Surgical instrument utilizing sensor adaptation

ABSTRACT

A surgical instrument can comprise a handle, a movable input, and an analog sensor configured to detect the position of the movable input, wherein the analog sensor is configured to produce an analog signal comprising analog data. The surgical instrument can further comprise a microcontroller comprising an input channel, wherein the analog sensor is in signal communication with the input channel, wherein the microcontroller is configured to compare the analog data to a reference value, and wherein the microcontroller is configured to produce a digital signal in response to the comparison.

BACKGROUND

The present invention relates to surgical instruments and, in variouscircumstances, to surgical stapling and cutting instruments and staplecartridges therefor that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of this invention, and the manner ofattaining them, will become more apparent and the invention itself willbe better understood by reference to the following description ofembodiments of the invention taken in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a perspective view of a surgical instrument that has aninterchangeable shaft assembly operably coupled thereto;

FIG. 2 is an exploded assembly view of the interchangeable shaftassembly and surgical instrument of FIG. 1;

FIG. 3 is another exploded assembly view showing portions of theinterchangeable shaft assembly and surgical instrument of FIGS. 1 and 2;

FIG. 4 is an exploded assembly view of a portion of the surgicalinstrument of FIGS. 1-3;

FIG. 5 is a cross-sectional side view of a portion of the surgicalinstrument of FIG. 4 with the firing trigger in a fully actuatedposition;

FIG. 6 is another cross-sectional view of a portion of the surgicalinstrument of FIG. 5 with the firing trigger in an unactuated position;

FIG. 7 is an exploded assembly view of one form of an interchangeableshaft assembly;

FIG. 8 is another exploded assembly view of portions of theinterchangeable shaft assembly of FIG. 7;

FIG. 9 is another exploded assembly view of portions of theinterchangeable shaft assembly of FIGS. 7 and 8;

FIG. 10 is a cross-sectional view of a portion of the interchangeableshaft assembly of FIGS. 7-9;

FIG. 11 is a perspective view of a portion of the shaft assembly ofFIGS. 7-10 with the switch drum omitted for clarity;

FIG. 12 is another perspective view of the portion of theinterchangeable shaft assembly of FIG. 11 with the switch drum mountedthereon;

FIG. 13 is a perspective view of a portion of the interchangeable shaftassembly of FIG. 11 operably coupled to a portion of the surgicalinstrument of FIG. 1 illustrated with the closure trigger thereof in anunactuated position;

FIG. 14 is a right side elevational view of the interchangeable shaftassembly and surgical instrument of FIG. 13;

FIG. 15 is a left side elevational view of the interchangeable shaftassembly and surgical instrument of FIGS. 13 and 14;

FIG. 16 is a perspective view of a portion of the interchangeable shaftassembly of FIG. 11 operably coupled to a portion of the surgicalinstrument of FIG. 1 illustrated with the closure trigger thereof in anactuated position and a firing trigger thereof in an unactuatedposition;

FIG. 17 is a right side elevational view of the interchangeable shaftassembly and surgical instrument of FIG. 16;

FIG. 18 is a left side elevational view of the interchangeable shaftassembly and surgical instrument of FIGS. 16 and 17;

FIG. 18A is a right side elevational view of the interchangeable shaftassembly of FIG. 11 operably coupled to a portion of the surgicalinstrument of FIG. 1 illustrated with the closure trigger thereof in anactuated position and the firing trigger thereof in an actuatedposition;

FIG. 19A is a first portion of a schematic for controlling a surgicalinstrument;

FIG. 19B is a second portion of the schematic of FIG. 19A;

FIG. 20 is a schematic of a switch circuit for use with a surgicalinstrument;

FIG. 21 is another schematic of a switch circuit for use with a surgicalinstrument;

FIG. 22A is a first portion of a schematic for controlling a surgicalinstrument utilizing the switch circuit of FIG. 21; and

FIG. 22B is a second portion of the schematic of FIG. 22A.

DETAILED DESCRIPTION

Applicant of the present application owns the following patentapplications that were filed on Mar. 1, 2013 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 13/782,295, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR SIGNAL COMMUNICATION;

U.S. patent application Ser. No. 13/782,323, entitled ROTARY POWEREDARTICULATION JOINTS FOR SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 13/782,338, entitled THUMBWHEEL SWITCHARRANGEMENTS FOR SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 13/782,499, entitled ELECTROMECHANICALSURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT;

U.S. patent application Ser. No. 13/782,460, entitled MULTIPLE PROCESSORMOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 13/782,358, entitled JOYSTICK SWITCHASSEMBLIES FOR SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 13/782,481, entitled SENSORSTRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR;

U.S. patent application Ser. No. 13/782,518, entitled CONTROL METHODSFOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS;

U.S. patent application Ser. No. 13/782,375, entitled ROTARY POWEREDSURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM; and

U.S. patent application Ser. No. 13/782,536, entitled SURGICALINSTRUMENT SOFT STOP are hereby incorporated by reference in theirentireties.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 14, 2013 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 13/803,097, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING A FIRING DRIVE;

U.S. patent application Ser. No. 13/803,193, entitled CONTROLARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT;

U.S. patent application Ser. No. 13/803,053, entitled INTERCHANGEABLESHAFT ASSEMBLIES FOR USE WITH A SURGICAL INSTRUMENT;

U.S. patent application Ser. No. 13/803,086, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK;

U.S. patent application Ser. No. 13/803,210, entitled SENSORARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 13/803,148, entitled MULTI-FUNCTIONMOTOR FOR A SURGICAL INSTRUMENT;

U.S. patent application Ser. No. 13/803,066, entitled DRIVE SYSTEMLOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 13/803,117, entitled ARTICULATIONCONTROL SYSTEM FOR ARTICULATABLE SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 13/803,130, entitled DRIVE TRAINCONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS; and

U.S. patent application Ser. No. 13/803,159, entitled METHOD AND SYSTEMFOR OPERATING A SURGICAL INSTRUMENT.

Applicant of the present application also owns the following patentapplications that were filed on even date herewith and are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTCOMPRISING A SENSOR SYSTEM, Attorney Docket No. END7386USNP/130458;

U.S. patent application Ser. No. ______, entitled POWER MANAGEMENTCONTROL SYSTEMS FOR SURGICAL INSTRUMENTS, Attorney Docket No.END7387USNP/130459;

U.S. patent application Ser. No. ______, entitled STERILIZATIONVERIFICATION CIRCUIT, Attorney Docket No. END7388USNP/130460;

U.S. patent application Ser. No. ______, entitled VERIFICATION OF NUMBEROF BATTERY EXCHANGES/PROCEDURE COUNT, Attorney Docket No.END7389USNP/130461;

U.S. patent application Ser. No. ______, entitled POWER MANAGEMENTTHROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE UP CONTROL, AttorneyDocket No. END7390USNP/130462;

U.S. patent application Ser. No. ______, entitled MODULAR POWEREDSURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES, Attorney DocketNo. END7391USNP/130463;

U.S. patent application Ser. No. ______, entitled FEEDBACK ALGORITHMSFOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS, Attorney Docket No.END7392USNP/130464;

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTCONTROL CIRCUIT HAVING A SAFETY PROCESSOR, Attorney Docket No.END7394USNP/130466;

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTCOMPRISING INTERACTIVE SYSTEMS, Attorney Docket No. END7395USNP/130467;

U.S. patent application Ser. No. ______, entitled INTERFACE SYSTEMS FORUSE WITH SURGICAL INSTRUMENTS, Attorney Docket No. END7396USNP/130468;

U.S. patent application Ser. No. ______, entitled MODULAR SURGICALINSTRUMENT SYSTEM, Attorney Docket No. END7397USNP/130469;

U.S. patent application Ser. No. ______, entitled SYSTEMS AND METHODSFOR CONTROLLING A SEGMENTED CIRCUIT, Attorney Docket No.END7399USNP/130471;

U.S. patent application Ser. No. ______, entitled POWER MANAGEMENTTHROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE PROTECTION, AttorneyDocket No. END7400USNP/130472;

U.S. patent application Ser. No. ______, entitled SURGICAL STAPLINGINSTRUMENT SYSTEM, Attorney Docket No. END7401USNP/130473; and

U.S. patent application Ser. No. ______, entitled SURGICAL INSTRUMENTCOMPRISING A ROTATABLE SHAFT, Attorney Docket No. END7402USNP/130474.

Certain exemplary embodiments will now be described to provide anoverall understanding of the principles of the structure, function,manufacture, and use of the devices and methods disclosed herein. One ormore examples of these embodiments are illustrated in the accompanyingdrawings. Those of ordinary skill in the art will understand that thedevices and methods specifically described herein and illustrated in theaccompanying drawings are non-limiting exemplary embodiments. Thefeatures illustrated or described in connection with one exemplaryembodiment may be combined with the features of other embodiments. Suchmodifications and variations are intended to be included within thescope of the present invention.

Reference throughout the specification to “various embodiments,” “someembodiments,” “one embodiment,” or “an embodiment”, or the like, meansthat a particular feature, structure, or characteristic described inconnection with the embodiment is included in at least one embodiment.Thus, appearances of the phrases “in various embodiments,” “in someembodiments,” “in one embodiment”, or “in an embodiment”, or the like,in places throughout the specification are not necessarily all referringto the same embodiment. Furthermore, the particular features,structures, or characteristics may be combined in any suitable manner inone or more embodiments. Thus, the particular features, structures, orcharacteristics illustrated or described in connection with oneembodiment may be combined, in whole or in part, with the featuresstructures, or characteristics of one or more other embodiments withoutlimitation. Such modifications and variations are intended to beincluded within the scope of the present invention.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” referring to the portion closest to the clinicianand the term “distal” referring to the portion located away from theclinician. It will be further appreciated that, for convenience andclarity, spatial terms such as “vertical,” “horizontal,” “up,” and“down” may be used herein with respect to the drawings. However,surgical instruments are used in many orientations and positions, andthese terms are not intended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, theperson of ordinary skill in the art will readily appreciate that thevarious methods and devices disclosed herein can be used in numeroussurgical procedures and applications including, for example, inconnection with open surgical procedures. As the present DetailedDescription proceeds, those of ordinary skill in the art will furtherappreciate that the various instruments disclosed herein can be insertedinto a body in any way, such as through a natural orifice, through anincision or puncture hole formed in tissue, etc. The working portions orend effector portions of the instruments can be inserted directly into apatient's body or can be inserted through an access device that has aworking channel through which the end effector and elongated shaft of asurgical instrument can be advanced.

FIGS. 1-6 depict a motor-driven surgical cutting and fasteninginstrument 10 that may or may not be reused. In the illustratedembodiment, the instrument 10 includes a housing 12 that comprises ahandle 14 that is configured to be grasped, manipulated and actuated bythe clinician. The housing 12 is configured for operable attachment toan interchangeable shaft assembly 200 that has a surgical end effector300 operably coupled thereto that is configured to perform one or moresurgical tasks or procedures. As the present Detailed Descriptionproceeds, it will be understood that the various unique and novelarrangements of the various forms of interchangeable shaft assembliesdisclosed herein may also be effectively employed in connection withrobotically-controlled surgical systems. Thus, the term “housing” mayalso encompass a housing or similar portion of a robotic system thathouses or otherwise operably supports at least one drive system that isconfigured to generate and apply at least one control motion which couldbe used to actuate the interchangeable shaft assemblies disclosed hereinand their respective equivalents. The term “frame” may refer to aportion of a handheld surgical instrument. The term “frame” may alsorepresent a portion of a robotically controlled surgical instrumentand/or a portion of the robotic system that may be used to operablycontrol a surgical instrument. For example, the interchangeable shaftassemblies disclosed herein may be employed with various roboticsystems, instruments, components and methods disclosed in U.S. patentapplication Ser. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTSWITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. PatentApplication Publication No. US 2012/0298719. U.S. patent applicationSer. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITHROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Patent ApplicationPublication No. US 2012/0298719, is incorporated by reference herein inits entirety.

The housing 12 depicted in FIGS. 1-3 is shown in connection with aninterchangeable shaft assembly 200 that includes an end effector 300that comprises a surgical cutting and fastening device that isconfigured to operably support a surgical staple cartridge 304 therein.The housing 12 may be configured for use in connection withinterchangeable shaft assemblies that include end effectors that areadapted to support different sizes and types of staple cartridges, havedifferent shaft lengths, sizes, and types, etc. In addition, the housing12 may also be effectively employed with a variety of otherinterchangeable shaft assemblies including those assemblies that areconfigured to apply other motions and forms of energy such as, forexample, radio frequency (RF) energy, ultrasonic energy and/or motion toend effector arrangements adapted for use in connection with varioussurgical applications and procedures. Furthermore, the end effectors,shaft assemblies, handles, surgical instruments, and/or surgicalinstrument systems can utilize any suitable fastener, or fasteners, tofasten tissue. For instance, a fastener cartridge comprising a pluralityof fasteners removably stored therein can be removably inserted intoand/or attached to the end effector of a shaft assembly.

FIG. 1 illustrates the surgical instrument 10 with an interchangeableshaft assembly 200 operably coupled thereto. FIGS. 2 and 3 illustrateattachment of the interchangeable shaft assembly 200 to the housing 12or handle 14. As can be seen in FIG. 4, the handle 14 may comprise apair of interconnectable handle housing segments 16 and 18 that may beinterconnected by screws, snap features, adhesive, etc. In theillustrated arrangement, the handle housing segments 16, 18 cooperate toform a pistol grip portion 19 that can be gripped and manipulated by theclinician. As will be discussed in further detail below, the handle 14operably supports a plurality of drive systems therein that areconfigured to generate and apply various control motions tocorresponding portions of the interchangeable shaft assembly that isoperably attached thereto.

Referring now to FIG. 4, the handle 14 may further include a frame 20that operably supports a plurality of drive systems. For example, theframe 20 can operably support a “first” or closure drive system,generally designated as 30, which may be employed to apply closing andopening motions to the interchangeable shaft assembly 200 that isoperably attached or coupled thereto. In at least one form, the closuredrive system 30 may include an actuator in the form of a closure trigger32 that is pivotally supported by the frame 20. More specifically, asillustrated in FIG. 4, the closure trigger 32 is pivotally coupled tothe housing 14 by a pin 33. Such arrangement enables the closure trigger32 to be manipulated by a clinician such that when the clinician gripsthe pistol grip portion 19 of the handle 14, the closure trigger 32 maybe easily pivoted from a starting or “unactuated” position to an“actuated” position and more particularly to a fully compressed or fullyactuated position. The closure trigger 32 may be biased into theunactuated position by spring or other biasing arrangement (not shown).In various forms, the closure drive system 30 further includes a closurelinkage assembly 34 that is pivotally coupled to the closure trigger 32.As can be seen in FIG. 4, the closure linkage assembly 34 may include afirst closure link 36 and a second closure link 38 that are pivotallycoupled to the closure trigger 32 by a pin 35. The second closure link38 may also be referred to herein as an “attachment member” and includea transverse attachment pin 37.

Still referring to FIG. 4, it can be observed that the first closurelink 36 may have a locking wall or end 39 thereon that is configured tocooperate with a closure release assembly 60 that is pivotally coupledto the frame 20. In at least one form, the closure release assembly 60may comprise a release button assembly 62 that has a distally protrudinglocking pawl 64 formed thereon. The release button assembly 62 may bepivoted in a counterclockwise direction by a release spring (not shown).As the clinician depresses the closure trigger 32 from its unactuatedposition towards the pistol grip portion 19 of the handle 14, the firstclosure link 36 pivots upward to a point wherein the locking pawl 64drops into retaining engagement with the locking wall 39 on the firstclosure link 36 thereby preventing the closure trigger 32 from returningto the unactuated position. See FIG. 18. Thus, the closure releaseassembly 60 serves to lock the closure trigger 32 in the fully actuatedposition. When the clinician desires to unlock the closure trigger 32 topermit it to be biased to the unactuated position, the clinician simplypivots the closure release button assembly 62 such that the locking pawl64 is moved out of engagement with the locking wall 39 on the firstclosure link 36. When the locking pawl 64 has been moved out ofengagement with the first closure link 36, the closure trigger 32 maypivot back to the unactuated position. Other closure trigger locking andrelease arrangements may also be employed.

Further to the above, FIGS. 13-15 illustrate the closure trigger 32 inits unactuated position which is associated with an open, or unclamped,configuration of the shaft assembly 200 in which tissue can bepositioned between the jaws of the shaft assembly 200. FIGS. 16-18illustrate the closure trigger 32 in its actuated position which isassociated with a closed, or clamped, configuration of the shaftassembly 200 in which tissue is clamped between the jaws of the shaftassembly 200. Upon comparing FIGS. 14 and 17, the reader will appreciatethat, when the closure trigger 32 is moved from its unactuated position(FIG. 14) to its actuated position (FIG. 17), the closure release button62 is pivoted between a first position (FIG. 14) and a second position(FIG. 17). The rotation of the closure release button 62 can be referredto as being an upward rotation; however, at least a portion of theclosure release button 62 is being rotated toward the circuit board 100.Referring to FIG. 4, the closure release button 62 can include an arm 61extending therefrom and a magnetic element 63, such as a permanentmagnet, for example, mounted to the arm 61. When the closure releasebutton 62 is rotated from its first position to its second position, themagnetic element 63 can move toward the circuit board 100. The circuitboard 100 can include at least one sensor configured to detect themovement of the magnetic element 63. In at least one embodiment, a Halleffect sensor 65, for example, can be mounted to the bottom surface ofthe circuit board 100. The Hall effect sensor 65 can be configured todetect changes in a magnetic field surrounding the Hall effect sensor 65caused by the movement of the magnetic element 63. The Hall effectsensor 65 can be in signal communication with a microcontroller 7004(FIG. 59), for example, which can determine whether the closure releasebutton 62 is in its first position, which is associated with theunactuated position of the closure trigger 32 and the open configurationof the end effector, its second position, which is associated with theactuated position of the closure trigger 32 and the closed configurationof the end effector, and/or any position between the first position andthe second position.

In at least one form, the handle 14 and the frame 20 may operablysupport another drive system referred to herein as a firing drive system80 that is configured to apply firing motions to corresponding portionsof the interchangeable shaft assembly attached thereto. The firing drivesystem may 80 also be referred to herein as a “second drive system”. Thefiring drive system 80 may employ an electric motor 82, located in thepistol grip portion 19 of the handle 14. In various forms, the motor 82may be a DC brushed driving motor having a maximum rotation of,approximately, 25,000 RPM, for example. In other arrangements, the motormay include a brushless motor, a cordless motor, a synchronous motor, astepper motor, or any other suitable electric motor. The motor 82 may bepowered by a power source 90 that in one form may comprise a removablepower pack 92. As can be seen in FIG. 4, for example, the power pack 92may comprise a proximal housing portion 94 that is configured forattachment to a distal housing portion 96. The proximal housing portion94 and the distal housing portion 96 are configured to operably supporta plurality of batteries 98 therein. Batteries 98 may each comprise, forexample, a Lithium Ion (“LI”) or other suitable battery. The distalhousing portion 96 is configured for removable operable attachment to acontrol circuit board assembly 100 which is also operably coupled to themotor 82. A number of batteries 98 may be connected in series may beused as the power source for the surgical instrument 10. In addition,the power source 90 may be replaceable and/or rechargeable.

As outlined above with respect to other various forms, the electricmotor 82 can include a rotatable shaft (not shown) that operablyinterfaces with a gear reducer assembly 84 that is mounted in meshingengagement with a with a set, or rack, of drive teeth 122 on alongitudinally-movable drive member 120. In use, a voltage polarityprovided by the power source 90 can operate the electric motor 82 in aclockwise direction wherein the voltage polarity applied to the electricmotor by the battery can be reversed in order to operate the electricmotor 82 in a counter-clockwise direction. When the electric motor 82 isrotated in one direction, the drive member 120 will be axially driven inthe distal direction “DD”. When the motor 82 is driven in the oppositerotary direction, the drive member 120 will be axially driven in aproximal direction “PD”. The handle 14 can include a switch which can beconfigured to reverse the polarity applied to the electric motor 82 bythe power source 90. As with the other forms described herein, thehandle 14 can also include a sensor that is configured to detect theposition of the drive member 120 and/or the direction in which the drivemember 120 is being moved.

Actuation of the motor 82 can be controlled by a firing trigger 130 thatis pivotally supported on the handle 14. The firing trigger 130 may bepivoted between an unactuated position and an actuated position. Thefiring trigger 130 may be biased into the unactuated position by aspring 132 or other biasing arrangement such that when the clinicianreleases the firing trigger 130, it may be pivoted or otherwise returnedto the unactuated position by the spring 132 or biasing arrangement. Inat least one form, the firing trigger 130 can be positioned “outboard”of the closure trigger 32 as was discussed above. In at least one form,a firing trigger safety button 134 may be pivotally mounted to theclosure trigger 32 by pin 35. The safety button 134 may be positionedbetween the firing trigger 130 and the closure trigger 32 and have apivot arm 136 protruding therefrom. See FIG. 4. When the closure trigger32 is in the unactuated position, the safety button 134 is contained inthe handle 14 where the clinician cannot readily access it and move itbetween a safety position preventing actuation of the firing trigger 130and a firing position wherein the firing trigger 130 may be fired. Asthe clinician depresses the closure trigger 32, the safety button 134and the firing trigger 130 pivot down wherein they can then bemanipulated by the clinician.

As discussed above, the handle 14 can include a closure trigger 32 and afiring trigger 130. Referring to FIGS. 14-18A, the firing trigger 130can be pivotably mounted to the closure trigger 32. The closure trigger32 can include an arm 31 extending therefrom and the firing trigger 130can be pivotably mounted to the arm 31 about a pivot pin 33. When theclosure trigger 32 is moved from its unactuated position (FIG. 14) toits actuated position (FIG. 17), the firing trigger 130 can descenddownwardly, as outlined above. After the safety button 134 has beenmoved to its firing position, referring primarily to FIG. 18A, thefiring trigger 130 can be depressed to operate the motor of the surgicalinstrument firing system. In various instances, the handle 14 caninclude a tracking system, such as system 800, for example, configuredto determine the position of the closure trigger 32 and/or the positionof the firing trigger 130. With primary reference to FIGS. 14, 17, and18A, the tracking system 800 can include a magnetic element, such aspermanent magnet 802, for example, which is mounted to an arm 801extending from the firing trigger 130. The tracking system 800 cancomprise one or more sensors, such as a first Hall effect sensor 803 anda second Hall effect sensor 804, for example, which can be configured totrack the position of the magnet 802. Upon comparing FIGS. 14 and 17,the reader will appreciate that, when the closure trigger 32 is movedfrom its unactuated position to its actuated position, the magnet 802can move between a first position adjacent the first Hall effect sensor803 and a second position adjacent the second Hall effect sensor 804.Upon comparing FIGS. 17 and 18A, the reader will further appreciatethat, when the firing trigger 130 is moved from an unfired position(FIG. 17) to a fired position (FIG. 18A), the magnet 802 can moverelative to the second Hall effect sensor 804. The sensors 803 and 804can track the movement of the magnet 802 and can be in signalcommunication with a microcontroller on the circuit board 100. With datafrom the first sensor 803 and/or the second sensor 804, themicrocontroller can determine the position of the magnet 802 along apredefined path and, based on that position, the microcontroller candetermine whether the closure trigger 32 is in its unactuated position,its actuated position, or a position therebetween. Similarly, with datafrom the first sensor 803 and/or the second sensor 804, themicrocontroller can determine the position of the magnet 802 along apredefined path and, based on that position, the microcontroller candetermine whether the firing trigger 130 is in its unfired position, itsfully fired position, or a position therebetween.

As indicated above, in at least one form, the longitudinally movabledrive member 120 has a rack of teeth 122 formed thereon for meshingengagement with a corresponding drive gear 86 of the gear reducerassembly 84. At least one form also includes a manually-actuatable“bailout” assembly 140 that is configured to enable the clinician tomanually retract the longitudinally movable drive member 120 should themotor 82 become disabled. The bailout assembly 140 may include a leveror bailout handle assembly 142 that is configured to be manually pivotedinto ratcheting engagement with teeth 124 also provided in the drivemember 120. Thus, the clinician can manually retract the drive member120 by using the bailout handle assembly 142 to ratchet the drive member120 in the proximal direction “PD”. U.S. Patent Application PublicationNo. US 2010/0089970 discloses bailout arrangements and other components,arrangements and systems that may also be employed with the variousinstruments disclosed herein. U.S. patent application Ser. No.12/249,117, entitled POWERED SURGICAL CUTTING AND STAPLING APPARATUSWITH MANUALLY RETRACTABLE FIRING SYSTEM, now U.S. Patent ApplicationPublication No. 2010/0089970, is hereby incorporated by reference in itsentirety.

Turning now to FIGS. 1 and 7, the interchangeable shaft assembly 200includes a surgical end effector 300 that comprises an elongated channel302 that is configured to operably support a staple cartridge 304therein. The end effector 300 may further include an anvil 306 that ispivotally supported relative to the elongated channel 302. Theinterchangeable shaft assembly 200 may further include an articulationjoint 270 and an articulation lock 350 (FIG. 8) which can be configuredto releasably hold the end effector 300 in a desired position relativeto a shaft axis SA-SA. Details regarding the construction and operationof the end effector 300, the articulation joint 270 and the articulationlock 350 are set forth in U.S. patent application Ser. No. 13/803,086,filed Mar. 14, 2013, entitled ARTICULATABLE SURGICAL INSTRUMENTCOMPRISING AN ARTICULATION LOCK. The entire disclosure of U.S. patentapplication Ser. No. 13/803,086, filed Mar. 14, 2013, entitledARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK ishereby incorporated by reference herein. As can be seen in FIGS. 7 and8, the interchangeable shaft assembly 200 can further include a proximalhousing or nozzle 201 comprised of nozzle portions 202 and 203. Theinterchangeable shaft assembly 200 can further include a closure tube260 which can be utilized to close and/or open the anvil 306 of the endeffector 300. Primarily referring now to FIGS. 8 and 9, the shaftassembly 200 can include a spine 210 which can be configured to fixablysupport a shaft frame portion 212 of the articulation lock 350. See FIG.8. The spine 210 can be configured to, one, slidably support a firingmember 220 therein and, two, slidably support the closure tube 260 whichextends around the spine 210. The spine 210 can also be configured toslidably support a proximal articulation driver 230. The articulationdriver 230 has a distal end 231 that is configured to operably engagethe articulation lock 350. The articulation lock 350 interfaces with anarticulation frame 352 that is adapted to operably engage a drive pin(not shown) on the end effector frame (not shown). As indicated above,further details regarding the operation of the articulation lock 350 andthe articulation frame may be found in U.S. patent application Ser. No.13/803,086. In various circumstances, the spine 210 can comprise aproximal end 211 which is rotatably supported in a chassis 240. In onearrangement, for example, the proximal end 211 of the spine 210 has athread 214 formed thereon for threaded attachment to a spine bearing 216configured to be supported within the chassis 240. See FIG. 7. Such anarrangement facilitates rotatable attachment of the spine 210 to thechassis 240 such that the spine 210 may be selectively rotated about ashaft axis SA-SA relative to the chassis 240.

Referring primarily to FIG. 7, the interchangeable shaft assembly 200includes a closure shuttle 250 that is slidably supported within thechassis 240 such that it may be axially moved relative thereto. As canbe seen in FIGS. 3 and 7, the closure shuttle 250 includes a pair ofproximally-protruding hooks 252 that are configured for attachment tothe attachment pin 37 that is attached to the second closure link 38 aswill be discussed in further detail below. A proximal end 261 of theclosure tube 260 is coupled to the closure shuttle 250 for relativerotation thereto. For example, a U shaped connector 263 is inserted intoan annular slot 262 in the proximal end 261 of the closure tube 260 andis retained within vertical slots 253 in the closure shuttle 250. SeeFIG. 7. Such an arrangement serves to attach the closure tube 260 to theclosure shuttle 250 for axial travel therewith while enabling theclosure tube 260 to rotate relative to the closure shuttle 250 about theshaft axis SA-SA. A closure spring 268 is journaled on the closure tube260 and serves to bias the closure tube 260 in the proximal direction“PD” which can serve to pivot the closure trigger into the unactuatedposition when the shaft assembly is operably coupled to the handle 14.

In at least one form, the interchangeable shaft assembly 200 may furtherinclude an articulation joint 270. Other interchangeable shaftassemblies, however, may not be capable of articulation. As can be seenin FIG. 7, for example, the articulation joint 270 includes a doublepivot closure sleeve assembly 271. According to various forms, thedouble pivot closure sleeve assembly 271 includes an end effectorclosure sleeve assembly 272 having upper and lower distally projectingtangs 273, 274. An end effector closure sleeve assembly 272 includes ahorseshoe aperture 275 and a tab 276 for engaging an opening tab on theanvil 306 in the various manners described in U.S. patent applicationSer. No. 13/803,086, filed Mar. 14, 2013, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK which has beenincorporated by reference herein. As described in further detailtherein, the horseshoe aperture 275 and tab 276 engage a tab on theanvil when the anvil 306 is opened. An upper double pivot link 277includes upwardly projecting distal and proximal pivot pins that engagerespectively an upper distal pin hole in the upper proximally projectingtang 273 and an upper proximal pin hole in an upper distally projectingtang 264 on the closure tube 260. A lower double pivot link 278 includesupwardly projecting distal and proximal pivot pins that engagerespectively a lower distal pin hole in the lower proximally projectingtang 274 and a lower proximal pin hole in the lower distally projectingtang 265. See also FIG. 8.

In use, the closure tube 260 is translated distally (direction “DD”) toclose the anvil 306, for example, in response to the actuation of theclosure trigger 32. The anvil 306 is closed by distally translating theclosure tube 260 and thus the shaft closure sleeve assembly 272, causingit to strike a proximal surface on the anvil 360 in the manner describedin the aforementioned reference U.S. patent application Ser. No.13/803,086. As was also described in detail in that reference, the anvil306 is opened by proximally translating the closure tube 260 and theshaft closure sleeve assembly 272, causing tab 276 and the horseshoeaperture 275 to contact and push against the anvil tab to lift the anvil306. In the anvil-open position, the shaft closure tube 260 is moved toits proximal position.

As indicated above, the surgical instrument 10 may further include anarticulation lock 350 of the types and construction described in furtherdetail in U.S. patent application Ser. No. 13/803,086 which can beconfigured and operated to selectively lock the end effector 300 inposition. Such arrangement enables the end effector 300 to be rotated,or articulated, relative to the shaft closure tube 260 when thearticulation lock 350 is in its unlocked state. In such an unlockedstate, the end effector 300 can be positioned and pushed against softtissue and/or bone, for example, surrounding the surgical site withinthe patient in order to cause the end effector 300 to articulaterelative to the closure tube 260. The end effector 300 may also bearticulated relative to the closure tube 260 by an articulation driver230.

As was also indicated above, the interchangeable shaft assembly 200further includes a firing member 220 that is supported for axial travelwithin the shaft spine 210. The firing member 220 includes anintermediate firing shaft portion 222 that is configured for attachmentto a distal cutting portion or knife bar 280. The firing member 220 mayalso be referred to herein as a “second shaft” and/or a “second shaftassembly”. As can be seen in FIGS. 8 and 9, the intermediate firingshaft portion 222 may include a longitudinal slot 223 in the distal endthereof which can be configured to receive a tab 284 on the proximal end282 of the distal knife bar 280. The longitudinal slot 223 and theproximal end 282 can be sized and configured to permit relative movementtherebetween and can comprise a slip joint 286. The slip joint 286 canpermit the intermediate firing shaft portion 222 of the firing drive 220to be moved to articulate the end effector 300 without moving, or atleast substantially moving, the knife bar 280. Once the end effector 300has been suitably oriented, the intermediate firing shaft portion 222can be advanced distally until a proximal sidewall of the longitudinalslot 223 comes into contact with the tab 284 in order to advance theknife bar 280 and fire the staple cartridge positioned within thechannel 302 As can be further seen in FIGS. 8 and 9, the shaft spine 210has an elongate opening or window 213 therein to facilitate assembly andinsertion of the intermediate firing shaft portion 222 into the shaftframe 210. Once the intermediate firing shaft portion 222 has beeninserted therein, a top frame segment 215 may be engaged with the shaftframe 212 to enclose the intermediate firing shaft portion 222 and knifebar 280 therein. Further description of the operation of the firingmember 220 may be found in U.S. patent application Ser. No. 13/803,086.

Further to the above, the shaft assembly 200 can include a clutchassembly 400 which can be configured to selectively and releasablycouple the articulation driver 230 to the firing member 220. In oneform, the clutch assembly 400 includes a lock collar, or sleeve 402,positioned around the firing member 220 wherein the lock sleeve 402 canbe rotated between an engaged position in which the lock sleeve 402couples the articulation driver 360 to the firing member 220 and adisengaged position in which the articulation driver 360 is not operablycoupled to the firing member 200. When lock sleeve 402 is in its engagedposition, distal movement of the firing member 220 can move thearticulation driver 360 distally and, correspondingly, proximal movementof the firing member 220 can move the articulation driver 230proximally. When lock sleeve 402 is in its disengaged position, movementof the firing member 220 is not transmitted to the articulation driver230 and, as a result, the firing member 220 can move independently ofthe articulation driver 230. In various circumstances, the articulationdriver 230 can be held in position by the articulation lock 350 when thearticulation driver 230 is not being moved in the proximal or distaldirections by the firing member 220.

Referring primarily to FIG. 9, the lock sleeve 402 can comprise acylindrical, or an at least substantially cylindrical, body including alongitudinal aperture 403 defined therein configured to receive thefiring member 220. The lock sleeve 402 can comprisediametrically-opposed, inwardly-facing lock protrusions 404 and anoutwardly-facing lock member 406. The lock protrusions 404 can beconfigured to be selectively engaged with the firing member 220. Moreparticularly, when the lock sleeve 402 is in its engaged position, thelock protrusions 404 are positioned within a drive notch 224 defined inthe firing member 220 such that a distal pushing force and/or a proximalpulling force can be transmitted from the firing member 220 to the locksleeve 402. When the lock sleeve 402 is in its engaged position, thesecond lock member 406 is received within a drive notch 232 defined inthe articulation driver 230 such that the distal pushing force and/orthe proximal pulling force applied to the lock sleeve 402 can betransmitted to the articulation driver 230. In effect, the firing member220, the lock sleeve 402, and the articulation driver 230 will movetogether when the lock sleeve 402 is in its engaged position. On theother hand, when the lock sleeve 402 is in its disengaged position, thelock protrusions 404 may not be positioned within the drive notch 224 ofthe firing member 220 and, as a result, a distal pushing force and/or aproximal pulling force may not be transmitted from the firing member 220to the lock sleeve 402. Correspondingly, the distal pushing force and/orthe proximal pulling force may not be transmitted to the articulationdriver 230. In such circumstances, the firing member 220 can be slidproximally and/or distally relative to the lock sleeve 402 and theproximal articulation driver 230.

As can be seen in FIGS. 8-12, the shaft assembly 200 further includes aswitch drum 500 that is rotatably received on the closure tube 260. Theswitch drum 500 comprises a hollow shaft segment 502 that has a shaftboss 504 formed thereon for receive an outwardly protruding actuationpin 410 therein. In various circumstances, the actuation pin 410 extendsthrough a slot 267 into a longitudinal slot 408 provided in the locksleeve 402 to facilitate axial movement of the lock sleeve 402 when itis engaged with the articulation driver 230. A rotary torsion spring 420is configured to engage the boss 504 on the switch drum 500 and aportion of the nozzle housing 203 as shown in FIG. 10 to apply a biasingforce to the switch drum 500. The switch drum 500 can further compriseat least partially circumferential openings 506 defined therein which,referring to FIGS. 5 and 6, can be configured to receive circumferentialmounts 204, 205 extending from the nozzle halves 202, 203 and permitrelative rotation, but not translation, between the switch drum 500 andthe proximal nozzle 201. As can be seen in those Figures, the mounts 204and 205 also extend through openings 266 in the closure tube 260 to beseated in recesses 211 in the shaft spine 210. However, rotation of thenozzle 201 to a point where the mounts 204, 205 reach the end of theirrespective slots 506 in the switch drum 500 will result in rotation ofthe switch drum 500 about the shaft axis SA-SA. Rotation of the switchdrum 500 will ultimately result in the rotation of eth actuation pin 410and the lock sleeve 402 between its engaged and disengaged positions.Thus, in essence, the nozzle 201 may be employed to operably engage anddisengage the articulation drive system with the firing drive system inthe various manners described in further detail in U.S. patentapplication Ser. No. 13/803,086.

As also illustrated in FIGS. 8-12, the shaft assembly 200 can comprise aslip ring assembly 600 which can be configured to conduct electricalpower to and/or from the end effector 300 and/or communicate signals toand/or from the end effector 300, for example. The slip ring assembly600 can comprise a proximal connector flange 604 mounted to a chassisflange 242 extending from the chassis 240 and a distal connector flange601 positioned within a slot defined in the shaft housings 202, 203. Theproximal connector flange 604 can comprise a first face and the distalconnector flange 601 can comprise a second face which is positionedadjacent to and movable relative to the first face. The distal connectorflange 601 can rotate relative to the proximal connector flange 604about the shaft axis SA-SA. The proximal connector flange 604 cancomprise a plurality of concentric, or at least substantiallyconcentric, conductors 602 defined in the first face thereof. Aconnector 607 can be mounted on the proximal side of the connectorflange 601 and may have a plurality of contacts (not shown) wherein eachcontact corresponds to and is in electrical contact with one of theconductors 602. Such an arrangement permits relative rotation betweenthe proximal connector flange 604 and the distal connector flange 601while maintaining electrical contact therebetween. The proximalconnector flange 604 can include an electrical connector 606 which canplace the conductors 602 in signal communication with a shaft circuitboard 610 mounted to the shaft chassis 240, for example. In at least oneinstance, a wiring harness comprising a plurality of conductors canextend between the electrical connector 606 and the shaft circuit board610. The electrical connector 606 may extend proximally through aconnector opening 243 defined in the chassis mounting flange 242. SeeFIG. 7. U.S. patent application Ser. No. 13/800,067, entitled STAPLECARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, isincorporated by reference in its entirety. U.S. patent application Ser.No. 13/800,025, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSORSYSTEM, filed on Mar. 13, 2013, is incorporated by reference in itsentirety. Further details regarding slip ring assembly 600 may be foundin U.S. patent application Ser. No. 13/803,086.

As discussed above, the shaft assembly 200 can include a proximalportion which is fixably mounted to the handle 14 and a distal portionwhich is rotatable about a longitudinal axis. The rotatable distal shaftportion can be rotated relative to the proximal portion about the slipring assembly 600, as discussed above. The distal connector flange 601of the slip ring assembly 600 can be positioned within the rotatabledistal shaft portion. Moreover, further to the above, the switch drum500 can also be positioned within the rotatable distal shaft portion.When the rotatable distal shaft portion is rotated, the distal connectorflange 601 and the switch drum 500 can be rotated synchronously with oneanother. In addition, the switch drum 500 can be rotated between a firstposition and a second position relative to the distal connector flange601. When the switch drum 500 is in its first position, the articulationdrive system may be operably disengaged from the firing drive systemand, thus, the operation of the firing drive system may not articulatethe end effector 300 of the shaft assembly 200. When the switch drum 500is in its second position, the articulation drive system may be operablyengaged with the firing drive system and, thus, the operation of thefiring drive system may articulate the end effector 300 of the shaftassembly 200. When the switch drum 500 is moved between its firstposition and its second position, the switch drum 500 is moved relativeto distal connector flange 601. In various instances, the shaft assembly200 can comprise at least one sensor configured to detect the positionof the switch drum 500. Turning now to FIGS. 11 and 12, the distalconnector flange 601 can comprise a Hall effect sensor 605, for example,and the switch drum 500 can comprise a magnetic element, such aspermanent magnet 505, for example. The Hall effect sensor 605 can beconfigured to detect the position of the permanent magnet 505. When theswitch drum 500 is rotated between its first position and its secondposition, the permanent magnet 505 can move relative to the Hall effectsensor 605. In various instances, Hall effect sensor 605 can detectchanges in a magnetic field created when the permanent magnet 505 ismoved. The Hall effect sensor 605 can be in signal communication withthe shaft circuit board 610 and/or the handle circuit board 100, forexample. Based on the signal from the Hall effect sensor 605, amicrocontroller on the shaft circuit board 610 and/or the handle circuitboard 100 can determine whether the articulation drive system is engagedwith or disengaged from the firing drive system.

Referring again to FIGS. 3 and 7, the chassis 240 includes at least one,and preferably two, tapered attachment portions 244 formed thereon thatare adapted to be received within corresponding dovetail slots 702formed within a distal attachment flange portion 700 of the frame 20.Each dovetail slot 702 may be tapered or, stated another way, besomewhat V-shaped to seatingly receive the attachment portions 244therein. As can be further seen in FIGS. 3 and 7, a shaft attachment lug226 is formed on the proximal end of the intermediate firing shaft 222.As will be discussed in further detail below, when the interchangeableshaft assembly 200 is coupled to the handle 14, the shaft attachment lug226 is received in a firing shaft attachment cradle 126 formed in thedistal end 125 of the longitudinal drive member 120. See FIGS. 3 and 6.

Various shaft assembly embodiments employ a latch system 710 forremovably coupling the shaft assembly 200 to the housing 12 and morespecifically to the frame 20. As can be seen in FIG. 7, for example, inat least one form, the latch system 710 includes a lock member or lockyoke 712 that is movably coupled to the chassis 240. In the illustratedembodiment, for example, the lock yoke 712 has a U-shape with two spaceddownwardly extending legs 714. The legs 714 each have a pivot lug 716formed thereon that are adapted to be received in corresponding holes245 formed in the chassis 240. Such arrangement facilitates pivotalattachment of the lock yoke 712 to the chassis 240. The lock yoke 712may include two proximally protruding lock lugs 714 that are configuredfor releasable engagement with corresponding lock detents or grooves 704in the distal attachment flange 700 of the frame 20. See FIG. 3. Invarious forms, the lock yoke 712 is biased in the proximal direction byspring or biasing member (not shown). Actuation of the lock yoke 712 maybe accomplished by a latch button 722 that is slidably mounted on alatch actuator assembly 720 that is mounted to the chassis 240. Thelatch button 722 may be biased in a proximal direction relative to thelock yoke 712. As will be discussed in further detail below, the lockyoke 712 may be moved to an unlocked position by biasing the latchbutton the in distal direction which also causes the lock yoke 712 topivot out of retaining engagement with the distal attachment flange 700of the frame 20. When the lock yoke 712 is in “retaining engagement”with the distal attachment flange 700 of the frame 20, the lock lugs 716are retainingly seated within the corresponding lock detents or grooves704 in the distal attachment flange 700.

When employing an interchangeable shaft assembly that includes an endeffector of the type described herein that is adapted to cut and fastentissue, as well as other types of end effectors, it may be desirable toprevent inadvertent detachment of the interchangeable shaft assemblyfrom the housing during actuation of the end effector. For example, inuse the clinician may actuate the closure trigger 32 to grasp andmanipulate the target tissue into a desired position. Once the targettissue is positioned within the end effector 300 in a desiredorientation, the clinician may then fully actuate the closure trigger 32to close the anvil 306 and clamp the target tissue in position forcutting and stapling. In that instance, the first drive system 30 hasbeen fully actuated. After the target tissue has been clamped in the endeffector 300, it may be desirable to prevent the inadvertent detachmentof the shaft assembly 200 from the housing 12. One form of the latchsystem 710 is configured to prevent such inadvertent detachment.

As can be most particularly seen in FIG. 7, the lock yoke 712 includesat least one and preferably two lock hooks 718 that are adapted tocontact corresponding lock lug portions 256 that are formed on theclosure shuttle 250. Referring to FIGS. 13-15, when the closure shuttle250 is in an unactuated position (i.e., the first drive system 30 isunactuated and the anvil 306 is open), the lock yoke 712 may be pivotedin a distal direction to unlock the interchangeable shaft assembly 200from the housing 12. When in that position, the lock hooks 718 do notcontact the lock lug portions 256 on the closure shuttle 250. However,when the closure shuttle 250 is moved to an actuated position (i.e., thefirst drive system 30 is actuated and the anvil 306 is in the closedposition), the lock yoke 712 is prevented from being pivoted to anunlocked position. See FIGS. 16-18. Stated another way, if the clinicianwere to attempt to pivot the lock yoke 712 to an unlocked position or,for example, the lock yoke 712 was in advertently bumped or contacted ina manner that might otherwise cause it to pivot distally, the lock hooks718 on the lock yoke 712 will contact the lock lugs 256 on the closureshuttle 250 and prevent movement of the lock yoke 712 to an unlockedposition.

Attachment of the interchangeable shaft assembly 200 to the handle 14will now be described with reference to FIG. 3. To commence the couplingprocess, the clinician may position the chassis 240 of theinterchangeable shaft assembly 200 above or adjacent to the distalattachment flange 700 of the frame 20 such that the tapered attachmentportions 244 formed on the chassis 240 are aligned with the dovetailslots 702 in the frame 20. The clinician may then move the shaftassembly 200 along an installation axis IA that is perpendicular to theshaft axis SA-SA to seat the attachment portions 244 in “operableengagement” with the corresponding dovetail receiving slots 702. Indoing so, the shaft attachment lug 226 on the intermediate firing shaft222 will also be seated in the cradle 126 in the longitudinally movabledrive member 120 and the portions of pin 37 on the second closure link38 will be seated in the corresponding hooks 252 in the closure yoke250. As used herein, the term “operable engagement” in the context oftwo components means that the two components are sufficiently engagedwith each other so that upon application of an actuation motion thereto,the components may carry out their intended action, function and/orprocedure.

As discussed above, at least five systems of the interchangeable shaftassembly 200 can be operably coupled with at least five correspondingsystems of the handle 14. A first system can comprise a frame systemwhich couples and/or aligns the frame or spine of the shaft assembly 200with the frame 20 of the handle 14. Another system can comprise aclosure drive system 30 which can operably connect the closure trigger32 of the handle 14 and the closure tube 260 and the anvil 306 of theshaft assembly 200. As outlined above, the closure tube attachment yoke250 of the shaft assembly 200 can be engaged with the pin 37 on thesecond closure link 38. Another system can comprise the firing drivesystem 80 which can operably connect the firing trigger 130 of thehandle 14 with the intermediate firing shaft 222 of the shaft assembly200. As outlined above, the shaft attachment lug 226 can be operablyconnected with the cradle 126 of the longitudinal drive member 120.Another system can comprise an electrical system which can signal to acontroller in the handle 14, such as microcontroller, for example, thata shaft assembly, such as shaft assembly 200, for example, has beenoperably engaged with the handle 14 and/or, two, conduct power and/orcommunication signals between the shaft assembly 200 and the handle 14.For instance, the shaft assembly 200 can include an electrical connector4010 that is operably mounted to the shaft circuit board 610. Theelectrical connector 4010 is configured for mating engagement with acorresponding electrical connector 4000 on the handle control board 100.Further details regaining the circuitry and control systems may be foundin U.S. patent application Ser. No. 13/803,086, the entire disclosure ofwhich was previously incorporated by reference herein. The fifth systemmay consist of the latching system for releasably locking the shaftassembly 200 to the handle 14.

As described herein, a surgical instrument, such as a surgical staplinginstrument, for example, can include a processor, computer, and/orcontroller, for example, (herein collectively referred to as a“processor”) and one or more sensors in signal communication with theprocessor, computer, and/or controller. In various instances, aprocessor can comprise a microcontroller and one or more memory unitsoperationally coupled to the microcontroller. By executing instructioncode stored in the memory, the processor may control various componentsof the surgical instrument, such as the motor, various drive systems,and/or a user display, for example. The processor may be implementedusing integrated and/or discrete hardware elements, software elements,and/or a combination of both. Examples of integrated hardware elementsmay include processors, microprocessors, microcontrollers, integratedcircuits, application specific integrated circuits (ASIC), programmablelogic devices (PLD), digital signal processors (DSP), field programmablegate arrays (FPGA), logic gates, registers, semiconductor devices,chips, microchips, chip sets, microcontrollers, system-on-chip (SoC),and/or system-in-package (SIP). Examples of discrete hardware elementsmay include circuits and/or circuit elements such as logic gates, fieldeffect transistors, bipolar transistors, resistors, capacitors,inductors, and/or relays. In certain instances, the processor mayinclude a hybrid circuit comprising discrete and integrated circuitelements or components on one or more substrates, for example.

The processor may be an LM 4F230H5QR, available from Texas Instruments,for example. In certain instances, the Texas Instruments LM4F230H5QR isan ARM Cortex-M4F Processor Core comprising on-chip memory of 256 KBsingle-cycle flash memory, or other non-volatile memory, up to 40 MHz, aprefetch buffer to improve performance above 40 MHz, a 32 KBsingle-cycle serial random access memory (SRAM), internal read-onlymemory (ROM) loaded with StellarisWare® software, 2 KB electricallyerasable programmable read-only memory (EEPROM), one or more pulse widthmodulation (PWM) modules, one or more quadrature encoder inputs (QEDanalog, one or more 12-bit Analog-to-Digital Converters (ADC) with 12analog input channels, among other features that are readily available.Other microcontrollers may be readily substituted for use with thepresent disclosure. Accordingly, the present disclosure should not belimited in this context.

Signal communication can comprise any suitable form of communication inwhich information is transmitted between a sensor and the processor.Such communication can comprise wired communication utilizing one ormore conductors and/or wireless communication utilizing a wirelesstransmitter and receiver, for example. In various instances, a surgicalinstrument can include a first sensor configured to detect a firstcondition of the surgical instrument and a second sensor configured todetect a second condition of the surgical instrument. For instance, thesurgical instrument can include a first sensor configured to detectwhether a closure trigger of the surgical instrument has been actuatedand a second sensor configured to detect whether a firing trigger of thesurgical instrument has been actuated, for example.

Various embodiments are envisioned in which the surgical instrument caninclude two or more sensors configured to detect the same condition. Inat least one such embodiment, the surgical instrument can comprise aprocessor, a first sensor in signal communication with the processor,and a second sensor in signal communication with the processor. Thefirst sensor can be configured to communicate a first signal to theprocessor and the second sensor can be configured to communicate asecond signal to the processor. In various instances, the processor caninclude a first input channel for receiving the first signal from thefirst sensor and a second input channel for receiving the second signalfrom the second sensor. In other instances, a multiplexer device canreceive the first signal and the second signal and communicate the dataof the first and second signals to the processor as part of a single,combined signal, for example. In some instances, a first conductor, suchas a first insulated wire, for example, can connect the first sensor tothe first input channel and a second conductor, such as a secondinsulated wire, for example, can connect the second sensor to the secondinput channel. As outlined above, the first sensor and/or the secondsensor can communicate wirelessly with the processor. In at least onesuch instance, the first sensor can include a first wireless transmitterand the second sensor can include a second wireless transmitter, whereinthe processor can include and/or can be in communication with at leastone wireless signal receiver configured to receive the first signaland/or the second signal and transmit the signals to the processor.

In co-operation with the sensors, as described in greater detail below,the processor of the surgical instrument can verify that the surgicalinstrument is operating correctly. The first signal can include dataregarding a condition of the surgical instrument and the second signalcan include data regarding the same condition. The processor can includean algorithm configured to compare the data from the first signal to thedata from the second signal and determine whether the data communicatedby the two signals are the same or different. If the data from the twosignals are the same, the processor may use the data to operate thesurgical instrument. In such circumstances, the processor can assumethat a fault condition does not exist. In various instances, theprocessor can determine whether the data from the first signal and thedata from the second signal are within an acceptable, or recognized,range of data. If the data from the two signals are within therecognized range of data, the processor may use the data from one orboth of the signals to operate the surgical instrument. In suchcircumstances, the processor can assume that a fault condition does notexist. If the data from the first signal is outside of the recognizedrange of data, the processor may assume that a fault condition existswith regard to the first sensor, ignore the first signal, and operatethe surgical instrument in response to the data from the second signal.Likewise, if the data from the second signal is outside the recognizedrange of data, the processor may assume that a fault condition existswith regard to the second sensor, ignore the second signal, and operatethe surgical instrument in response to the data from the first signal.The processor can be configured to selectively ignore the input from oneor more sensors.

In various instances, further to the above, the processor can include amodule configured to implement an algorithm configured to assess whetherthe data from the first signal is between a first value and a secondvalue. Similarly, the algorithm can be configured to assess whether thedata from the second signal is between the first value and the secondvalue. In certain instances, a surgical instrument can include at leastone memory device. A memory device can be integral with the processor,in signal communication with the processor, and/or accessible by theprocessor. In certain instances, the memory device can include a memorychip including data stored thereon. The data stored on the memory chipcan be in the form of a lookup table, for example, wherein the processorcan access the lookup table to establish the acceptable, or recognized,range of data. In certain instances, the memory device can comprisenonvolatile memory, such as bit-masked read-only memory (ROM) or flashmemory, for example. Nonvolatile memory (NVM) may comprise other typesof memory including, for example, programmable ROM (PROM), erasableprogrammable ROM (EPROM), electrically erasable programmable ROM(EEPROM), or battery backed random-access memory (RAM) such as dynamicRAM (DRAM), Double-Data-Rate DRAM (DDRAM), and/or synchronous DRAM(SDRAM).

Further to the above, the first sensor and the second sensor can beredundant. The processor can be configured to compare the first signalfrom the first sensor to the second signal from the second sensor todetermine what action, if any, to take. In addition to or in lieu of theabove, the processor can be configured to compare the data from thefirst signal and/or the second signal to limits established by thealgorithm and/or data stored within a memory device. In variouscircumstances, the processor can be configured to apply a gain to asignal it receives, such as the first signal and/or the second signal,for example. For instance, the processor can apply a first gain to thefirst signal and a second gain to the second signal. In certaininstances, the first gain can be the same as the second gain. In otherinstances, the first gain and the second gain can be different. In somecircumstances, the processor can be configured to calibrate the firstgain and/or the second gain. In at least one such circumstance, theprocessor can modify a gain such that the amplified signal is within adesired, or acceptable, range. In various instances, the unmodified gainand/or the modified gain can be stored within a memory device which isintegral to and/or accessible by the processor. In certain embodiments,the memory device can track the history of the gains applied to asignal. In any event, the processor can be configured to provide thiscalibration before, during, and/or after a surgical procedure.

In various embodiments, the first sensor can apply a first gain to thefirst signal and the second sensor can apply a second gain to the secondsignal. In certain embodiments, the processor can include one or moreoutput channels and can communicate with the first and second sensors.For instance, the processor can include a first output channel in signalcommunication with the first sensor and a second output channel insignal communication with the second sensor. Further to the above, theprocessor can be configured to calibrate the first sensor and/or thesecond sensor. The processor can send a first calibration signal throughsaid first output channel in order to modify a first gain that the firstsensor is applying to the first signal. Similarly, the processor cansend a second calibration signal through said second output channel inorder to modify a second gain that the second sensor is applying to thesecond signal.

As discussed above, the processor can modify the operation of thesurgical instrument in view of the data received from the first signaland/or the second signal. In some circumstances, the processor canignore the signal from a redundant sensor that the processor deems to befaulty. In some circumstances, the processor can return the surgicalinstrument to a safe state and/or warn the user of the surgicalinstrument that one or both of the sensors may be faulty. In certaincircumstances, the processor can disable the surgical instrument. Invarious circumstances, the processor can deactivate and/or modifycertain functions of the surgical instrument when the processor detectsthat one or more of the sensors may be faulty. In at least one suchcircumstance, the processor may limit the operable controls to thosecontrols which can permit the surgical instrument to be safely removedfrom the surgical site, for example, when the processor detects that oneor more of the sensors may be faulty. In at least one circumstance, whenthe processor detects that one or more of the sensors may be faulty. Incertain circumstances, the processor may limit the maximum speed, power,and/or torque that can be delivered by the motor of the surgicalinstrument, for example, when the processor detects that one or more ofthe sensors may be faulty. In various circumstances, the processor mayenable a recalibration control which may allow the user of the surgicalinstrument to recalibrate the mal-performing or non-performing sensor,for example, when the processor detects that one or more of the sensorsmay be faulty. While various exemplary embodiments utilizing two sensorsto detect the same condition are described herein, various otherembodiments are envisioned which utilize more than two sensors. Theprinciples applied to the two sensor system described herein can beadapted to systems including three or more sensors.

As discussed above, the first sensor and the second sensor can beconfigured to detect the same condition of the surgical instrument. Forinstance, the first sensor and the second sensor can be configured todetect whether an anvil of the surgical instrument is in an opencondition, for example. In at least one such instance, the first sensorcan detect the movement of a closure trigger into an actuated positionand the second sensor can detect the movement of an anvil into a clampedposition, for example. In some instances, the first sensor and thesecond sensor can be configured to detect the position of a firingmember configured to deploy staples from an end effector of the surgicalinstrument. In at least one such instance, the first sensor can beconfigured to detect the position of a motor-driven rack in a handle ofthe surgical instrument and the second sensor can be configured todetect the position of a firing member in a shaft or an end effector ofthe surgical instrument which is operably coupled with the motor-drivenrack, for example. In various instances, the first and second sensorscould verify that the same event is occurring. The first and secondsensors could be located in the same portion of the surgical instrumentand/or in different portions of the surgical instrument. A first sensorcan be located in the handle, for example, and a second sensor could belocated in the shaft or the end effector, for example.

Further to the above, the first and second sensors can be utilized todetermine whether two events are occurring at the same time. Forexample, whether the closure trigger and the anvil are moving, or havemoved, concurrently. In certain instances, the first and second sensorscan be utilized to determine whether two events are not occurring at thesame time. For example, it may not be desirable for the anvil of the endeffector to open while the firing member of the surgical instrument isbeing advanced to deploy the staples from the end effector. The firstsensor can be configured to determine whether the anvil is in an clampedposition and the second sensor can be configured to determine whetherthe firing member is being advanced. In the event that the first sensordetects that the anvil is in an unclamped position while the secondsensor detects that the firing member is being advanced, the processorcan interrupt the supply of power to the motor of the surgicalinstrument, for example. Similarly, the first sensor can be configuredto detect whether an unclamping actuator configured to unclamp the endeffector has been depressed and the second sensor can be configured todetect whether a firing actuator configured to operate the motor of thesurgical instrument has been depressed. The processor of the surgicalinstrument can be configured to resolve these conflicting instructionsby stopping the motor, reversing the motor to retract the firing member,and/or ignoring the instructions from the unclamping actuator, forexample.

In some instances, further to the above, the condition detected caninclude the power consumed by the surgical instrument. In at least onesuch instance, the first sensor can be configured to monitor the currentdrawn from a battery of the surgical instrument and the second sensorcan be configured to monitor the voltage of the battery. As discussedabove, such information can be communicated from the first sensor andthe second sensor to the processor. With this information, the processorcan calculate the electrical power draw of the surgical instrument. Sucha system could be referred to as ‘supply side’ power monitoring. Incertain instances, the first sensor can be configured to detect thecurrent drawn by a motor of the surgical instrument and the secondsensor can be configured to detect the current drawn by a processor ofthe surgical instrument, for example. As discussed above, suchinformation can be communicated from the first sensor and the secondsensor to the processor. With this information, the processor cancalculate the electrical power draw of the surgical instrument. To theextent that other components of the surgical instrument draw electricalpower, a sensor could be utilized to detect the current drawn for eachcomponent and communicate that information to the processor. Such asystem could be referred to as ‘use side’ power monitoring. Variousembodiments are envisioned which utilize supply side power monitoringand use side power monitoring. In various instances, the processor,and/or an algorithm implemented by the processor, can be configured tocalculate a state of the device using more than one sensor that may notbe sensed directly by only one sensor. Based on this calculation, theprocessor can enable, block, and/or modify a function of the surgicalinstrument.

In various circumstances, the condition of the surgical instrument thatcan be detected by a processor and a sensor system can include theorientation of the surgical instrument. In at least one embodiment, thesurgical instrument can include a handle, a shaft extending from thehandle, and an end effector extending from the shaft. A first sensor canbe positioned within the handle and a second sensor can be positionedwithin the shaft, for example. The first sensor can comprise a firsttilt sensor and the second sensor can comprise a second tilt sensor, forexample. The first tilt sensor can be configured to detect theinstrument's orientation with respect to a first plane and the secondtilt sensor can be configured to detect the instrument's orientationwith respect to a second plane. The first plane and the second plane mayor may not be orthogonal. The first sensor can comprise an accelerometerand/or a gyroscope, for example. The second sensor can comprise anaccelerometer and/or a gyroscope, for example. Various embodiments areenvisioned which comprise more than two sensors and each such sensor cancomprise an accelerometer and/or a gyroscope, for example. In at leastone implementation, a first sensor can comprise a first accelerometerarranged along a first axis and a second sensor can comprise a secondaccelerometer arranged along a second axis which is different than thefirst axis. In at least one such instance, the first axis can betransverse to the second axis.

Further to the above, the processor can utilize data from the first andsecond accelerometers to determine the direction in which gravity isacting with respect to the instrument, i.e., the direction of groundwith respect to the surgical instrument. In certain instances, magneticfields generated in the environment surrounding the surgical instrumentmay affect one of the accelerometers. Further to the above, theprocessor can be configured to ignore data from an accelerometer if thedata from the accelerometers is inconsistent. Moreover, the processorcan be configured to ignore data from an accelerometer if theaccelerometer is dithering between two or more strong polarityorientations, for example. To the extent that an external magnetic fieldis affecting two or more, and/or all, of the accelerometers of asurgical instrument, the processor can deactivate certain functions ofthe surgical instrument which depend on data from the accelerometers. Invarious instances, a surgical instrument can include a screen configuredto display images communicated to the screen by the processor, whereinthe processor can be configured to change the orientation of the imagesdisplayed on the screen when the handle of the surgical instrument isreoriented, or at least when a reorientation of the handle is detectedby the accelerometers. In at least one instance, the display on thescreen can be flipped upside down when the handle is oriented upsidedown. In the event that the processor determines that orientation datafrom one or more of the accelerometers may be faulty, the processor mayprevent the display from being reoriented away from its defaultposition, for example.

Further to the above, the orientation of a surgical instrument may ormay not be detectable from a single sensor. In at least one instance,the handle of the surgical instrument can include a first sensor and theshaft can include a second sensor, for example. Utilizing data from thefirst sensor and the second sensor, and/or data from any other sensor,the processor can determine the orientation of the surgical instrument.In some instances, the processor can utilize an algorithm configured tocombine the data from the first sensor signal, the second sensor signal,and/or any suitable number of sensor signals to determine theorientation of the surgical instrument. In at least one instance, ahandle sensor positioned within the handle can determine the orientationof the handle with respect to gravity. A shaft sensor positioned withinthe shaft can determine the orientation of the shaft with respect togravity. In embodiments where the shaft, or at least a portion of theshaft, does not articulate relative to the handle, the processor candetermine the direction in which the shaft, or the non-articulated shaftportion, is pointing. In some instances, a surgical instrument caninclude an end effector which can articulate relative to the shaft. Thesurgical instrument can include an articulation sensor which candetermine the direction and the degree in which the end effector hasbeen articulated relative to the shaft, for example. With data from thehandle sensor, the shaft sensor, and the articulation sensor, theprocessor can determine the direction in which the end effector ispointing. With additional data including the length of the handle, theshaft, and/or the end effector, the processor can determine the positionof the distal tip of the end effector, for example. With suchinformation, the processor could enable, block, and/or modify a functionof the surgical instrument.

In various instances, a surgical instrument can include a redundantprocessor in addition to a first processor. The redundant processor canbe in signal communication with some or all of the sensors that thefirst processor is in signal communication with. The redundant processorcan perform some or all of the same calculations that the firstprocessor performs. The redundant processor can be in signalcommunication with the first processor. The first processor can beconfigured to compare the calculations that it has performed with thecalculations that the redundant processor has performed. Similarly, theredundant processor can be configured to compare the calculations thatit has performed with the calculations that the first processor hasperformed. In various instances, the first processor and the redundantprocessor can be configured to operate the surgical instrumentindependently of one another. In some instances, the first processorand/or the redundant processor can be configured to determine whetherthe other processor is faulty and/or deactivate the other processor if afault within the other processor and/or within the surgical instrumentis detected. The first processor and the redundant processor can both beconfigured to communicate with the operator of the surgical instrumentsuch that, if one of the processors determines the other processor to befaulty, the non-faulty processor can communicate with the operator thata fault condition exists, for example.

In various embodiments, a surgical instrument can include a processorand one or more sensors in signal communication with the processor. Thesensors can comprise digital sensors and/or analog sensors. A digitalsensor can generate a measuring signal and can include an electronicchip. The electronic chip can convert the measuring signal into adigital output signal. The digital output signal can then be transmittedto the processor utilizing a suitable transmission means such as, forexample, a conductive cable, a fiber optic cable, and/or a wirelessemitter. An analog sensor can generate a measuring signal andcommunicate the measuring signal to the processor using an analog outputsignal. An analog sensor can include a Hall Effect sensor, amagnetoresistive sensor, an optical sensor, and/or any other suitablesensor, for example. A surgical instrument can include a signal filterwhich can be configured to receive and/or condition the analog outputsignal before the analog output signal reaches the processor. The signalfilter can comprise a low-pass filter, for example, that passes signalsto the processor having a low frequency which is at and/or below acutoff frequency and that attenuates, or reduces the amplitude of,signals with high frequencies higher than the cutoff frequency. In someinstances, the low-pass filter may eliminate certain high frequencysignals that it receives or all of the high frequency signals that itreceives. The low-pass filter may also attenuate, or reduce theamplitude of, certain or all of the low frequency signals, but suchattenuation may be different than the attenuation that it applies tohigh frequency signals. Any suitable signal filter could be utilized. Ahigh-pass filter, for example, could be utilized. A longpass filtercould be utilized to receive and condition signals from optical sensors.In various instances, the processor can include an integral signalfilter. In some instances, the processor can be in signal communicationwith the signal filter. In any event, the signal filter can beconfigured to reduce noise within the analog output signal, or signals,that it receives.

Further to the above, an analog output signal from a sensor can comprisea series of voltage potentials applied to an input channel of theprocessor. In various instances, the voltage potentials of the analogsensor output signal can be within a defined range. For instance, thevoltage potentials can be between about 0V and about 12V, between about0V and about 6V, between about 0V and about 3V, and/or between about 0Vand about 1V, for example. In some instances, the voltage potentials canbe less than or equal to 12V, less than or equal to 6V, less than orequal to 3V, and/or less than or equal to 1V, for example. In someinstances, the voltage potentials can be between about 0V and about−12V, between about 0V and about −6V, between about 0V and about −3V,and/or between about 0V and about −1V, for example. In some instances,the voltage potentials can be greater than or equal to −12V, greaterthan or equal to −6V, greater than or equal to −3V, and/or greater thanor equal to −1V, for example. In some instances, the voltage potentialscan be between about 12V and about −12V, between about 6V and about −6V,between about 3V and about −3V, and/or between about 1V and about −1V,for example. In various instances, the sensor can supply voltagepotentials to an input channel of the processor in a continuous stream.The processor may sample this stream of data at a rate which is lessthan rate in which data is delivered to the processor. In someinstances, the sensor can supply voltage potentials to an input channelof the process intermittently or at periodic intervals. In any event,the processor can be configured to evaluate the voltage potentialsapplied to the input channel or channels thereof and operate thesurgical instrument in response to the voltage potentials, as describedin greater detail further below.

Further to the above, the processor can be configured to evaluate theanalog output signal from a sensor. In various instances, the processorcan be configured to evaluate every voltage potential of the analogoutput signal and/or sample the analog output signal. When sampling theanalog output signal, the processor can make periodic evaluations of thesignal to periodically obtain voltage potentials from the analog outputsignal. For each evaluation, the processor can compare the voltagepotential obtained from the evaluation against a reference value. Invarious circumstances, the processor can calculate a digital value, suchas 0 or 1, or on or off, for example, from this comparison. Forinstance, in the event that the evaluated voltage potential equals thereference value, the processor can calculate a digital value of 1.Alternatively, the processor can calculate a digital value of 0 if theevaluated voltage potential equals the reference value. With regard to afirst embodiment, the processor can calculate a digital value of 1 ifthe evaluated voltage potential is less than the reference value and adigital value of 0 if the evaluated voltage potential is greater thanthe reference value. With regard to a second embodiment, the processorcan calculate a digital value of 0 if the evaluated voltage potential isless than the reference value and a digital value of 1 if the evaluatedvoltage potential is greater than the reference value. In either event,the processor can convert the analog signal to a digital signal. Whenthe processor is continuously evaluating the voltage potential of thesensor output signal, the processor can continuously compare the voltagepotential to the reference value, and continuously calculate the digitalvalue. When the processor is evaluating the voltage potential of thesensor output signal at periodic intervals, the processor can comparethe voltage potential to the reference value at periodic intervals, andcalculate the digital value at periodic intervals.

Further to the above, the reference value can be part of an algorithmutilized by the processor. The reference value can be pre-programmed inthe algorithm. In some instances, the processor can obtain, calculate,and/or modify the reference value in the algorithm. In some instances,the reference value can be stored in a memory device which is accessibleby and/or integral with the processor. The reference value can bepre-programmed in the memory device. In some instances, the processorcan obtain, calculate, and/or modify the reference value in the memorydevice. In at least one instance, the reference value may be stored innon-volatile memory. In some instances, the reference value may bestored in volatile memory. The reference value may comprise a constantvalue. The reference value may or may not be changeable or overwritten.In certain instances, the reference value can be stored, changed, and/orotherwise determined as the result of a calibration procedure. Thecalibration procedure can be performed when manufacturing the surgicalinstrument, when initializing, or initially powering up, the instrument,when powering up the instrument from a sleep mode, when using theinstrument, when placing the instrument into a sleep mode, and/or whencompletely powering down the instrument, for example.

Also further to the above, the processor can be configured to store thedigital value. The digital value can be stored at an electronic logicgate. In various instances, the electronic logic gate can supply abinary output which can be referenced by the processor to assess acondition detected by the sensor, as described in greater detail furtherbelow. The processor can include the electronic logic gate. The binaryoutput of the electronic logic gate can be updated. In variousinstances, the processor can include one or more output channels. Theprocessor can supply the binary output to at least one of the outputchannels. The processor can apply a low voltage to such an outputchannel to indicate an off bit or a high voltage to the output channelto indicate an on bit, for example. The low voltage and the high voltagecan be measured relative to a threshold value. In at least one instance,the low voltage can comprise no voltage, for example. In at least oneother instance, the low voltage can comprise a voltage having a firstpolarity and the high voltage can comprise a voltage having an oppositepolarity, for example.

In at least one instance, if the voltage potentials evaluated by theprocessor are consistently at or below the reference value, theelectronic logic gate can maintain an output of ‘on’. When an evaluatedvoltage potential exceeds the reference value, the output of the logicgate can be switched to ‘off’. If the voltage potentials evaluated bythe processor are consistently above the reference value, the electroniclogic gate can maintain an output of ‘off’. When an evaluated voltagepotential is thereafter measured at or below the reference value, theoutput of the logic gate can be switched back to ‘on’, and so forth. Invarious instances, the electronic logic gate may not maintain a historyof its output. In some instances, the processor can include a memorydevice configured to record the output history of the electronic logicgate, i.e., record a history of the calculated digital value. In variousinstances, the processor can be configured to access the memory deviceto ascertain the current digital value and/or at least onepreviously-existing digital value, for example.

In various instances, the processor can provide an immediate response toa change in the calculated digital value. When the processor firstdetects that the calculated digital value has changed from ‘on’ to ‘off’or from ‘off’ to ‘on’, for example, the processor can immediately modifythe operation of the surgical instrument. In certain instances, theprocessor may not immediately modify the operation of the surgicalinstrument upon detecting that the calculated digital value has changedfrom ‘on’ to ‘off’ or from ‘off’ to ‘on’, for example. The processor mayemploy a hysteresis algorithm. For instance, the processor may notmodify the operation of the surgical instrument until after the digitalvalue has been calculated the same way a certain number of consecutivetimes. In at least one such instance, the processor may calculate an‘on’ value and display an ‘on’ binary value at the output logic gateand/or the output channel based on the data it has received from one ormore surgical instrument sensors wherein, at some point thereafter, theprocessor may calculate an ‘off’ value based on the data it has receivedfrom one or more of the surgical instrument sensors; however, theprocessor may not immediately display an ‘off’ binary value at theoutput logic gate and/or the output channel. Rather, the processor maydelay changing the binary value at the output logic gate and/or theoutput channel until after the processor has calculated the ‘off’ valuea certain number of consecutive times, such as ten times, for example.Once the processor has changed the binary value at the output logic gateand/or the output channel, the processor may likewise delay changing thebinary value at the output logic gate and/or the output channel untilafter the processor has calculated the ‘on’ value a certain number ofconsecutive times, such as ten times, for example, and so forth.

A hysteresis algorithm may be suitable for handling switch debounce. Asurgical instrument can include a switch debouncer circuit whichutilizes a capacitor to filter out any quick changes of signal response.

In the example provided above, the sampling delay for going from ‘on’ to‘off’ was the same as the sampling delay for going from ‘off’ to ‘on’.Embodiments are envisioned in which the sampling delays are not equal.For instance, if an ‘on’ value at an output channel activates the motorof the surgical instrument and an ‘off’ value at an output channeldeactivates the motor, the ‘on’ delay may be longer than the ‘off’delay, for example. In such instances, the processor may not suddenlyactivate the motor in response to accidental or incidental movements ofthe firing trigger while, on the other hand, the processor may reactquickly to a release of the firing trigger to stop the motor. In atleast one such instance, the processor may have an ‘on’ delay but no‘off’ delay such that the motor can be stopped immediately after thefiring trigger is released, for example. As discussed above, theprocessor may wait for a certain number of consecutive consistent binaryoutput calculations before changing the binary output value. Otheralgorithms are contemplated. For instance, a processor may not require acertain number of consecutive consistent binary output calculations;rather, the processor may only require that a certain number, orpercentage, of consecutive calculations be consistent in order to changethe binary output.

As discussed above, a processor can convert an analog input signal to adigital output signal utilizing a reference value. As also discussedabove, the processor can utilize the reference value to convert theanalog input data, or samples of the analog input data, to ‘on’ valuesor ‘off’ values as part of its digital output signal. In variousinstances, a processor can utilize more than one reference value inorder to determine whether to output an ‘on’ value or an ‘off’ value.One reference value can define two ranges. A range below the referencevalue and a range above the reference value. The reference value itselfcan be part of the first range or the second range, depending on thecircumstances. The use of additional reference values can defineadditional ranges. For instance, a first reference value and a secondreference value can define three ranges: a first range below the firstreference value, a second range between the first reference value andthe second reference value, and a third range above the second referencevalue. Again, the first reference value can be part of the first rangeor the second range and, similarly, the second reference value can bepart of the second range or the third range, depending on thecircumstances. For a given sample of data from an analog signal, theprocessor can determine whether the sample lies within the first range,the second range, or the third range. In at least one exemplaryembodiment, the processor can assign an ‘on’ value to the binary outputif the sample is in the first range and an ‘off’ value to the binaryoutput if the sample is in the third range. Alternatively, the processorcan assign an ‘off’ value to the binary output if the sample is in thefirst range and an ‘on’ value to the binary output if the sample is inthe third range.

Further to the above, the processor can assign an ‘on’ value or an ‘off’value to the binary output if the data sample is in the second range. Invarious instances, an analog data sample in the second range may notchange the binary output value. For instance, if the processor has beenreceiving analog data above the second reference value and producing acertain binary output and, subsequently, the processor receives analogdata between the first reference value and the second reference value,the processor may not change the binary output. If the processor, inthis example, receives analog data below the first reference value, theprocessor may then change the binary output. Correspondingly, in thisexample, if the processor has been receiving analog data below the firstreference value and producing a certain binary output and, subsequently,the processor receives analog data between the first reference value andthe second reference value, the processor may not change the binaryoutput. If the processor, in this example, receives analog data abovethe second reference value, the processor may then change the binaryoutput. In various instances, the second range between the firstreference value and the second reference value may comprise anobservation window within which the processor may not change the binaryoutput signal. In certain instances, the processor may utilize differentsampling delays, depending on whether the analog input data jumpsdirectly between the first range and the third range or whether theanalog input data transitions into the second range before transitioninginto the third range. For example, the sampling delay may be shorter ifthe analog input data transitions into the second range beforetransitioning into the first range or the third range as compared towhen analog input data jumps directly between the first range and thethird range.

As discussed above, an analog sensor, such as a Hall effect sensor, forexample, can be utilized to detect a condition of a surgical instrument.In various instances, a Hall effect sensor can produce a linear analogoutput which can include a positive polarity and a negative polarityand, in certain instances, produce a wide range of analog output values.Such a wide range of values may not always be useful, or may notcorrespond to events which are actually possible for the surgicalinstrument. For instance, a Hall effect sensor can be utilized to trackthe orientation of the anvil of an end effector which, owing to certainphysical constraints to the motion of the anvil, may only move through asmall range of motion, such as about 30 degrees, for example. Althoughthe Hall effect sensor could detect motion of the anvil outside thisrange of motion, as a practical matter, the Hall effect sensor will notneed to and, as a result, a portion of the output range of the Halleffect sensor may not be utilized. The processor may be programmed toonly recognize a range of output from the Hall effect sensor whichcorresponds to a possible range of motion of the anvil and, to theextent that the processor receives data from the Hall effect sensorwhich is outside of this range of output, whether above the range orbelow the range, the processor can ignore such data, generate a faultcondition, modify the operation of the surgical instrument, and/ornotify the user of the surgical instrument, for example. In suchinstances, the processor may recognize a valid range of data from thesensor and any data received from the sensor which is outside of thisrange may be deemed invalid by the processor. The valid range of datamay be defined by a first reference value, or threshold, and a secondreference value, or threshold. The valid range of data may include datahaving a positive polarity and a negative polarity. Alternatively, thevalid range of data may only comprise data from the positive polarity ordata from the negative polarity.

The first reference value and the second reference value, further to theabove, can comprise fixed values. In certain circumstances, the firstreference value and/or the second reference value can be calibrated. Thefirst reference value and/or the second reference value can becalibrated when the surgical instrument is initially manufactured and/orsubsequently re-manufactured. For instance, a trigger, such as theclosure trigger, for example, can be moved through its entire range ofmotion during a calibration procedure and a Hall effect sensor, forexample, positioned within the surgical instrument handle can detect themotion of the closure trigger, or at least the motion of a magneticelement, such as a permanent magnet, for example, positioned on theclosure trigger. When the closure trigger is in its unclamped position,the reading taken by the Hall effect sensor can be stored as a first setpoint which corresponds with the unclamped position of the closuretrigger. Similarly, when the closure trigger is in its fully clampedposition, the reading taken by the Hall effect sensor can be stored as asecond set point which corresponds with the fully clamped position ofthe closure trigger. Thereafter, the first set point can define thefirst reference value and the second set point can define the secondreference value. Positions of the closure trigger between its unclampedposition and its fully clamped position can correspond to the range ofdata between the first reference value and the second reference value.As outlined above, the processor can produce a digital output value inresponse to the data received from the analog sensor. In at least oneinstance, the processor can assign an ‘off’ value to its digital outputwhen the data received from the analog sensor is at or above the firstreference value. Alternatively, the processor can assign an ‘off’ valueto its digital output when the data received from the analog sensor isabove, at, or within about 20% of the range preceding first referencevalue, for example. Data from the analog sensor which is between thefirst reference value and about 20% of the range below the firstreference value can correspond with a position of the closure triggerwhich is suitably close to is unclamped position. In at least oneinstance, the processor can assign an ‘on’ value to its digital outputwhen the data received from the analog sensor is below the firstreference value. Alternatively, the processor can assign an ‘on’ valueto its digital output when the data received from the analog sensor isat, below, or within about 40% of the range above the second referencevalue can correspond with a position of the closure trigger when it hasbeen pulled about ¾ through its range of motion, for example. The sameor similar attributes could be applied to a firing trigger of thesurgical instrument, for example.

Further to the above, a sensor can be calibrated in view of a referencevalue. For instance, if a reference value of +2V, for example, isassociated with an unclamped position of the closure trigger and theprocessor detects a sensor output value which is different than +2V whenthe closure trigger is in its unclamped position, the processor canrecalibrate the sensor, or the gain of the sensor, such that the sensoroutput matches, or at least substantially matches, the reference value.The processor may utilize an independent method of confirming that theclosure trigger is in its unclamped position. In at least one suchinstance, the surgical instrument can include a second sensor in signalcommunication with the processor which can independently verify that theclosure trigger is in its unclamped position. The second sensor couldalso comprise an analog sensor, such as a Hall effect sensor, forexample. The second sensor could comprise a proximity sensor, aresistance based sensor, and/or any other suitable sensor, for example.The same or similar attributes could be applied to a firing trigger ofthe surgical instrument, for example.

As discussed above, referring to FIGS. 14-18A, a tracking system 800 cancomprise one or more sensors, such as a first Hall effect sensor 803 anda second Hall effect sensor 804, for example, which can be configured totrack the position of the magnet 802. Upon comparing FIGS. 14 and 17,the reader will appreciate that, when the closure trigger 32 is movedfrom its unactuated position to its actuated position, the magnet 802can move between a first position adjacent the first Hall effect sensor803 and a second position adjacent the second Hall effect sensor 804.When the magnet 802 is in its first position, the position of the magnet802 can be detected by the first Hall effect sensor 803 and/or thesecond Hall effect sensor 804. The processor of the surgical instrumentcan use data from the first sensor 803 to determine the position of themagnet 802 and data from the second sensor 804 to independentlydetermine the position of the magnet 802. In such instances, theprocessor can utilize data from the second sensor 804 to verify theintegrity of the data from the first sensor 803. Alternatively, theprocessor could utilize the data from the first sensor 803 to verify theintegrity of the data from the second sensor 804. The processor canutilize any suitable hierarchy for determining whether the data from asensor should be used to provide a primary determination or a secondarydetermination of the position of the magnet 802. For instance, when themagnet 802 is in its first position, the magnet 802 may provide a largerdisturbance to the magnetic field surrounding the first sensor 803 thanto the magnetic field surrounding the second sensor 804 and, as aresult, the processor may utilize the data from the first sensor 803 asa primary determination of the position of the magnet 802. When themagnet 802 is closer to the second sensor 804 than the first sensor 803,the magnet 802 may provide a larger disturbance to the magnetic fieldsurrounding the second sensor 804 than to the magnetic field surroundingthe first sensor 803 and, as a result, the processor may utilize thedata from the second sensor 804 as a primary determination of theposition of the magnet 802.

Further to the above, the path of the magnet 802 relative to the firstsensor 803 can be determined when the magnet 802 moves along a firstpath segment when the closure trigger 32 is moved between its unclampedposition and its clamped position and a second path segment when thefiring trigger 130 is moved between its unfired position and its firedposition. The range of outputs that the first sensor 803 will producewhile tracking the magnet 802 as it moves along its first path segmentcan define a first valid range of data while the range of outputs thatthe first sensor 803 will produce while tracking the magnet 802 as itmoves along its second path segment can define a second valid range ofdata. The first valid range of data may or may not be contiguous withthe second valid range of data. In either event, the path of the magnet802 relative to the second sensor 804 can also be determined when themagnet 802 moves along its first path segment and its second pathsegment. The range of outputs that the second sensor 804 will producewhile tracking the magnet 802 as it moves along its first path segmentcan define a first valid range of data while the range of outputs thatthe second sensor 804 will produce while tracking the magnet 802 as itmoves along its second path segment can define a second valid range ofdata. When the first sensor 803 and/or the second sensor 804 receivesdata outside of its respective first valid range of data and secondvalid range of data, the processor may assume that an error hasoccurred, modify the operation of the surgical instrument, and/or notifythe operator of the surgical instrument. In certain instances, theprocessor can be configured to utilize data from the first sensor 803and the second sensor 804 to determine whether the surgical instrumenthas been positioned within a strong external magnetic field which canaffect the operation of the surgical instrument. For instance, themagnet 802 may move along a path such that the first sensor 803 and thesecond sensor 804 do not produce the same output at the same time and,in the event that first sensor 803 and the second sensor 804 produce thesame output at the same time, the processor can determine that a faultcondition exists, for example.

The entire disclosures of:

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U.S. patent application Ser. No. 12/031,873, entitled END EFFECTORS FORA SURGICAL CUTTING AND STAPLING INSTRUMENT, filed Feb. 15, 2008, nowU.S. Pat. No. 7,980,443

U.S. patent application Ser. No. 12/235,782, entitled MOTOR-DRIVENSURGICAL CUTTING INSTRUMENT, now U.S. Pat. No. 8,210,411;

U.S. patent application Ser. No. 12/249,117, entitled POWERED SURGICALCUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM,now U.S. Patent Application Publication No. 2010/0089970;

U.S. patent application Ser. No. 12/647,100, entitled MOTOR-DRIVENSURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR DIRECTIONAL CONTROLASSEMBLY, filed Dec. 24, 2009;

U.S. patent application Ser. No. 12/893,461, entitled STAPLE CARTRIDGE,filed Sep. 29, 2012, now U.S. Patent Application Publication No.2012/0074198;

U.S. patent application Ser. No. 13/036,647, entitled SURGICAL STAPLINGINSTRUMENT, filed Feb. 28, 2011, now U.S. Patent Application PublicationNo. 2011/0226837;

U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLINGINSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S.Patent Application Publication No. 2012/0298719;

U.S. patent application Ser. No. 13/524,049, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, filed on Jun. 15, 2012;

U.S. patent application Ser. No. 13/800,025, entitled STAPLE CARTRIDGETISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013;

U.S. patent application Ser. No. 13/800,067, entitled STAPLE CARTRIDGETISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013;

U.S. Patent Application Pub. No. 2007/0175955, entitled SURGICAL CUTTINGAND FASTENING INSTRUMENT WITH CLOSURE TRIGGER LOCKING MECHANISM, filedJan. 31, 2006; and

U.S. Patent Application Publication No. 2010/0264194, entitled SURGICALSTAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR, filed Apr. 22,2010, are hereby incorporated by reference herein.

In accordance with various embodiments, the surgical instrumentsdescribed herein may comprise one or more processors (e.g.,microprocessor, microcontroller) coupled to various sensors. Inaddition, to the processor(s), a storage (having operating logic) andcommunication interface, are coupled to each other.

The processor may be configured to execute the operating logic. Theprocessor may be any one of a number of single or multi-core processorsknown in the art. The storage may comprise volatile and non-volatilestorage media configured to store persistent and temporal (working) copyof the operating logic.

In various embodiments, the operating logic may be configured to processthe collected biometric associated with motion data of the user, asdescribed above. In various embodiments, the operating logic may beconfigured to perform the initial processing, and transmit the data tothe computer hosting the application to determine and generateinstructions. For these embodiments, the operating logic may be furtherconfigured to receive information from and provide feedback to a hostingcomputer. In alternate embodiments, the operating logic may beconfigured to assume a larger role in receiving information anddetermining the feedback. In either case, whether determined on its ownor responsive to instructions from a hosting computer, the operatinglogic may be further configured to control and provide feedback to theuser.

In various embodiments, the operating logic may be implemented ininstructions supported by the instruction set architecture (ISA) of theprocessor, or in higher level languages and compiled into the supportedISA. The operating logic may comprise one or more logic units ormodules. The operating logic may be implemented in an object orientedmanner. The operating logic may be configured to be executed in amulti-tasking and/or multi-thread manner. In other embodiments, theoperating logic may be implemented in hardware such as a gate array.

In various embodiments, the communication interface may be configured tofacilitate communication between a peripheral device and the computingsystem. The communication may include transmission of the collectedbiometric data associated with position, posture, and/or movement dataof the user's body part(s) to a hosting computer, and transmission ofdata associated with the tactile feedback from the host computer to theperipheral device. In various embodiments, the communication interfacemay be a wired or a wireless communication interface. An example of awired communication interface may include, but is not limited to, aUniversal Serial Bus (USB) interface. An example of a wirelesscommunication interface may include, but is not limited to, a Bluetoothinterface.

For various embodiments, the processor may be packaged together with theoperating logic. In various embodiments, the processor may be packagedtogether with the operating logic to form a System in Package (SiP). Invarious embodiments, the processor may be integrated on the same diewith the operating logic. In various embodiments, the processor may bepackaged together with the operating logic to form a System on Chip(SoC).

Various embodiments may be described herein in the general context ofcomputer executable instructions, such as software, program modules,and/or engines being executed by a processor. Generally, software,program modules, and/or engines include any software element arranged toperform particular operations or implement particular abstract datatypes. Software, program modules, and/or engines can include routines,programs, objects, components, data structures and the like that performparticular tasks or implement particular abstract data types. Animplementation of the software, program modules, and/or enginescomponents and techniques may be stored on and/or transmitted acrosssome form of computer-readable media. In this regard, computer-readablemedia can be any available medium or media useable to store informationand accessible by a computing device. Some embodiments also may bepracticed in distributed computing environments where operations areperformed by one or more remote processing devices that are linkedthrough a communications network. In a distributed computingenvironment, software, program modules, and/or engines may be located inboth local and remote computer storage media including memory storagedevices. A memory such as a random access memory (RAM) or other dynamicstorage device may be employed for storing information and instructionsto be executed by the processor. The memory also may be used for storingtemporary variables or other intermediate information during executionof instructions to be executed by the processor.

Although some embodiments may be illustrated and described as comprisingfunctional components, software, engines, and/or modules performingvarious operations, it can be appreciated that such components ormodules may be implemented by one or more hardware components, softwarecomponents, and/or combination thereof. The functional components,software, engines, and/or modules may be implemented, for example, bylogic (e.g., instructions, data, and/or code) to be executed by a logicdevice (e.g., processor). Such logic may be stored internally orexternally to a logic device on one or more types of computer-readablestorage media. In other embodiments, the functional components such assoftware, engines, and/or modules may be implemented by hardwareelements that may include processors, microprocessors, circuits, circuitelements (e.g., transistors, resistors, capacitors, inductors, and soforth), integrated circuits, application specific integrated circuits(ASIC), programmable logic devices (PLD), digital signal processors(DSP), field programmable gate array (FPGA), logic gates, registers,semiconductor device, chips, microchips, chip sets, and so forth.

Examples of software, engines, and/or modules may include softwarecomponents, programs, applications, computer programs, applicationprograms, system programs, machine programs, operating system software,middleware, firmware, software modules, routines, subroutines,functions, methods, procedures, software interfaces, application programinterfaces (API), instruction sets, computing code, computer code, codesegments, computer code segments, words, values, symbols, or anycombination thereof. Determining whether an embodiment is implementedusing hardware elements and/or software elements may vary in accordancewith any number of factors, such as desired computational rate, powerlevels, heat tolerances, processing cycle budget, input data rates,output data rates, memory resources, data bus speeds and other design orperformance constraints.

One or more of the modules described herein may comprise one or moreembedded applications implemented as firmware, software, hardware, orany combination thereof. One or more of the modules described herein maycomprise various executable modules such as software, programs, data,drivers, application program interfaces (APIs), and so forth. Thefirmware may be stored in a memory of the controller 2016 and/or thecontroller 2022 which may comprise a nonvolatile memory (NVM), such asin bit-masked read-only memory (ROM) or flash memory. In variousimplementations, storing the firmware in ROM may preserve flash memory.The nonvolatile memory (NVM) may comprise other types of memoryincluding, for example, programmable ROM (PROM), erasable programmableROM (EPROM), electrically erasable programmable ROM (EEPROM), or batterybacked random-access memory (RAM) such as dynamic RAM (DRAM),Double-Data-Rate DRAM (DDRAM), and/or synchronous DRAM (SDRAM).

In some cases, various embodiments may be implemented as an article ofmanufacture. The article of manufacture may include a computer readablestorage medium arranged to store logic, instructions and/or data forperforming various operations of one or more embodiments. In variousembodiments, for example, the article of manufacture may comprise amagnetic disk, optical disk, flash memory or firmware containingcomputer program instructions suitable for execution by a generalpurpose processor or application specific processor. The embodiments,however, are not limited in this context.

The functions of the various functional elements, logical blocks,modules, and circuits elements described in connection with theembodiments disclosed herein may be implemented in the general contextof computer executable instructions, such as software, control modules,logic, and/or logic modules executed by the processing unit. Generally,software, control modules, logic, and/or logic modules comprise anysoftware element arranged to perform particular operations. Software,control modules, logic, and/or logic modules can comprise routines,programs, objects, components, data structures and the like that performparticular tasks or implement particular abstract data types. Animplementation of the software, control modules, logic, and/or logicmodules and techniques may be stored on and/or transmitted across someform of computer-readable media. In this regard, computer-readable mediacan be any available medium or media useable to store information andaccessible by a computing device. Some embodiments also may be practicedin distributed computing environments where operations are performed byone or more remote processing devices that are linked through acommunications network. In a distributed computing environment,software, control modules, logic, and/or logic modules may be located inboth local and remote computer storage media including memory storagedevices.

Additionally, it is to be appreciated that the embodiments describedherein illustrate example implementations, and that the functionalelements, logical blocks, modules, and circuits elements may beimplemented in various other ways which are consistent with thedescribed embodiments. Furthermore, the operations performed by suchfunctional elements, logical blocks, modules, and circuits elements maybe combined and/or separated for a given implementation and may beperformed by a greater number or fewer number of components or modules.As will be apparent to those of skill in the art upon reading thepresent disclosure, each of the individual embodiments described andillustrated herein has discrete components and features which may bereadily separated from or combined with the features of any of the otherseveral aspects without departing from the scope of the presentdisclosure. Any recited method can be carried out in the order of eventsrecited or in any other order which is logically possible.

It is worthy to note that any reference to “one embodiment” or “anembodiment” means that a particular feature, structure, orcharacteristic described in connection with the embodiment is comprisedin at least one embodiment. The appearances of the phrase “in oneembodiment” or “in one aspect” in the specification are not necessarilyall referring to the same embodiment.

Unless specifically stated otherwise, it may be appreciated that termssuch as “processing,” “computing,” “calculating,” “determining,” or thelike, refer to the action and/or processes of a computer or computingsystem, or similar electronic computing device, such as a generalpurpose processor, a DSP, ASIC, FPGA or other programmable logic device,discrete gate or transistor logic, discrete hardware components, or anycombination thereof designed to perform the functions described hereinthat manipulates and/or transforms data represented as physicalquantities (e.g., electronic) within registers and/or memories intoother data similarly represented as physical quantities within thememories, registers or other such information storage, transmission ordisplay devices.

It is worthy to note that some embodiments may be described using theexpression “coupled” and “connected” along with their derivatives. Theseterms are not intended as synonyms for each other. For example, someembodiments may be described using the terms “connected” and/or“coupled” to indicate that two or more elements are in direct physicalor electrical contact with each other. The term “coupled,” however, alsomay mean that two or more elements are not in direct contact with eachother, but yet still co-operate or interact with each other. Withrespect to software elements, for example, the term “coupled” may referto interfaces, message interfaces, application program interface (API),exchanging messages, and so forth.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

The disclosed embodiments have application in conventional endoscopicand open surgical instrumentation as well as application inrobotic-assisted surgery.

Embodiments of the devices disclosed herein can be designed to bedisposed of after a single use, or they can be designed to be usedmultiple times. Embodiments may, in either or both cases, bereconditioned for reuse after at least one use. Reconditioning mayinclude any combination of the steps of disassembly of the device,followed by cleaning or replacement of particular pieces, and subsequentreassembly. In particular, embodiments of the device may bedisassembled, and any number of the particular pieces or parts of thedevice may be selectively replaced or removed in any combination. Uponcleaning and/or replacement of particular parts, embodiments of thedevice may be reassembled for subsequent use either at a reconditioningfacility, or by a surgical team immediately prior to a surgicalprocedure. Those skilled in the art will appreciate that reconditioningof a device may utilize a variety of techniques for disassembly,cleaning/replacement, and reassembly. Use of such techniques, and theresulting reconditioned device, are all within the scope of the presentapplication.

By way of example only, embodiments described herein may be processedbefore surgery. First, a new or used instrument may be obtained and whennecessary cleaned. The instrument may then be sterilized. In onesterilization technique, the instrument is placed in a closed and sealedcontainer, such as a plastic or TYVEK bag. The container and instrumentmay then be placed in a field of radiation that can penetrate thecontainer, such as gamma radiation, x-rays, or high-energy electrons.The radiation may kill bacteria on the instrument and in the container.The sterilized instrument may then be stored in the sterile container.The sealed container may keep the instrument sterile until it is openedin a medical facility. A device also may be sterilized using any othertechnique known in the art, including but not limited to beta or gammaradiation, ethylene oxide, or steam.

One skilled in the art will recognize that the herein describedcomponents (e.g., operations), devices, objects, and the discussionaccompanying them are used as examples for the sake of conceptualclarity and that various configuration modifications are contemplated.Consequently, as used herein, the specific exemplars set forth and theaccompanying discussion are intended to be representative of their moregeneral classes. In general, use of any specific exemplar is intended tobe representative of its class, and the non-inclusion of specificcomponents (e.g., operations), devices, and objects should not be takenlimiting.

With respect to the use of substantially any plural and/or singularterms herein, those having skill in the art can translate from theplural to the singular and/or from the singular to the plural as isappropriate to the context and/or application. The varioussingular/plural permutations are not expressly set forth herein for sakeof clarity.

The herein described subject matter sometimes illustrates differentcomponents contained within, or connected with, different othercomponents. It is to be understood that such depicted architectures aremerely examples and that in fact many other architectures may beimplemented which achieve the same functionality. In a conceptual sense,any arrangement of components to achieve the same functionality iseffectively “associated” such that the desired functionality isachieved. Hence, any two components herein combined to achieve aparticular functionality can be seen as “associated with” each othersuch that the desired functionality is achieved, irrespective ofarchitectures or intermedial components. Likewise, any two components soassociated also can be viewed as being “operably connected,” or“operably coupled,” to each other to achieve the desired functionality,and any two components capable of being so associated also can be viewedas being “operably couplable,” to each other to achieve the desiredfunctionality. Specific examples of operably couplable include but arenot limited to physically mateable and/or physically interactingcomponents, and/or wirelessly interactable, and/or wirelesslyinteracting components, and/or logically interacting, and/or logicallyinteractable components.

Some aspects may be described using the expression “coupled” and“connected” along with their derivatives. It should be understood thatthese terms are not intended as synonyms for each other. For example,some aspects may be described using the term “connected” to indicatethat two or more elements are in direct physical or electrical contactwith each other. In another example, some aspects may be described usingthe term “coupled” to indicate that two or more elements are in directphysical or electrical contact. The term “coupled,” however, also maymean that two or more elements are not in direct contact with eachother, but yet still co-operate or interact with each other.

In some instances, one or more components may be referred to herein as“configured to,” “configurable to,” “operable/operative to,”“adapted/adaptable,” “able to,” “conformable/conformed to,” etc. Thoseskilled in the art will recognize that “configured to” can generallyencompass active-state components and/or inactive-state componentsand/or standby-state components, unless context requires otherwise.

While particular aspects of the present subject matter described hereinhave been shown and described, it will be apparent to those skilled inthe art that, based upon the teachings herein, changes and modificationsmay be made without departing from the subject matter described hereinand its broader aspects and, therefore, the appended claims are toencompass within their scope all such changes and modifications as arewithin the true scope of the subject matter described herein. It will beunderstood by those within the art that, in general, terms used herein,and especially in the appended claims (e.g., bodies of the appendedclaims) are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.). It will be further understood by those within the art that when aspecific number of an introduced claim recitation is intended, such anintent will be explicitly recited in the claim, and in the absence ofsuch recitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to claims containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should typically be interpreted to mean “atleast one” or “one or more”); the same holds true for the use ofdefinite articles used to introduce claim recitations.

In addition, even when a specific number of an introduced claimrecitation is explicitly recited, those skilled in the art willrecognize that such recitation should typically be interpreted to meanat least the recited number (e.g., the bare recitation of “tworecitations,” without other modifiers, typically means at least tworecitations, or two or more recitations). Furthermore, in thoseinstances where a convention analogous to “at least one of A, B, and C,etc.” is used, in general such a construction is intended in the senseone having skill in the art would understand the convention (e.g., “asystem having at least one of A, B, and C” would include but not belimited to systems that have A alone, B alone, C alone, A and Btogether, A and C together, B and C together, and/or A, B, and Ctogether, etc.). In those instances where a convention analogous to “atleast one of A, B, or C, etc.” is used, in general such a constructionis intended in the sense one having skill in the art would understandthe convention (e.g., “a system having at least one of A, B, or C” wouldinclude but not be limited to systems that have A alone, B alone, Calone, A and B together, A and C together, B and C together, and/or A,B, and C together, etc.). It will be further understood by those withinthe art that typically a disjunctive word and/or phrase presenting twoor more alternative terms, whether in the description, claims, ordrawings, should be understood to contemplate the possibilities ofincluding one of the terms, either of the terms, or both terms unlesscontext dictates otherwise. For example, the phrase “A or B” will betypically understood to include the possibilities of “A” or “B” or “Aand B.”

With respect to the appended claims, those skilled in the art willappreciate that recited operations therein may generally be performed inany order. Also, although various operational flows are presented in asequence(s), it should be understood that the various operations may beperformed in other orders than those which are illustrated, or may beperformed concurrently. Examples of such alternate orderings may includeoverlapping, interleaved, interrupted, reordered, incremental,preparatory, supplemental, simultaneous, reverse, or other variantorderings, unless context dictates otherwise. Furthermore, terms like“responsive to,” “related to,” or other past-tense adjectives aregenerally not intended to exclude such variants, unless context dictatesotherwise.

In summary, numerous benefits have been described which result fromemploying the concepts described herein. The foregoing description ofthe one or more embodiments has been presented for purposes ofillustration and description. It is not intended to be exhaustive orlimiting to the precise form disclosed. Modifications or variations arepossible in light of the above teachings. The one or more embodimentswere chosen and described in order to illustrate principles andpractical application to thereby enable one of ordinary skill in the artto utilize the various embodiments and with various modifications as aresuited to the particular use contemplated. It is intended that theclaims submitted herewith define the overall scope.

What is claimed is:
 1. A surgical instrument, comprising: a handle; amovable input; an analog sensor configured to detect the position ofsaid movable input, wherein said analog sensor is configured to producean analog signal comprising analog data; and a microcontrollercomprising an input channel, wherein said analog sensor is in signalcommunication with said input channel, wherein said microcontroller isconfigured to compare said analog data to a reference value, and whereinsaid microcontroller is configured to produce a digital signal inresponse to said comparison.
 2. The surgical instrument of claim 1,wherein said microcontroller is configured to sample said analog data,and wherein said microcontroller is configured to generate a digital bitfor each sample of said analog data.
 3. The surgical instrument of claim2, wherein said microcontroller is configured to generate an on bit if asample is above said reference value, and wherein said microcontrolleris configured to generate an off bit if a sample is below said referencevalue.
 4. The surgical instrument of claim 2, wherein said referencevalue comprises a first reference value, and wherein saidmicrocontroller is configured to compare said analog data to a secondreference value.
 5. The surgical instrument of claim 4, wherein saidmicrocontroller is configured to generate an on bit if a sample isbetween said first reference value and said second reference value,wherein said microcontroller is configured to generate an off bit if asample is below said first reference value, and wherein saidmicrocontroller can be configured to generate a fault condition if asample is above said second reference value.
 6. The surgical instrumentof claim 4, wherein said microcontroller is configured to generate an onbit if a sample is between said first reference value and said secondreference value, wherein said microcontroller is configured to generatean off bit if a sample is above said first reference value, and whereinsaid microcontroller can be configured to generate a fault condition ifa sample is below said second reference value.
 7. The surgicalinstrument of claim 1, wherein said microcontroller is configured tosample said analog data, wherein said microcontroller comprises anoutput channel, wherein said microcontroller is configured tocommunicate said digital signal to said output channel, wherein saidreference value comprises a first reference value, wherein saidmicrocontroller is configured to compare said analog data to a secondreference value, wherein said microcontroller is configured to changesaid digital signal if a sample is below said first reference value orabove said second reference value, and wherein said microcontroller isconfigured to not change said digital signal if a sample is between saidfirst reference value and said second reference value.
 8. The surgicalinstrument of claim 1, wherein said microcontroller is configured tosample said analog data, wherein said microcontroller comprises anoutput channel, wherein said microcontroller is configured tocommunicate said digital signal to said output channel, wherein saidreference value comprises a first reference value, wherein saidmicrocontroller is configured to compare said analog data to a secondreference value, wherein said microcontroller is configured to supply anoff bit to said output channel if a sample is less than said firstreference value, wherein said microcontroller is configured to supply anon bit to said output channel if a sample is greater than said secondreference value, and wherein said microcontroller is configured to notchange said digital signal if a sample is between said first referencevalue and said second reference value.
 9. The surgical instrument ofclaim 1, wherein said analog sensor comprises a Hall effect sensor,wherein said movable input comprises a magnetic element, and wherein themovement of said magnetic element is detectable by said Hall effectsensor.
 10. The surgical instrument of claim 1, wherein said analogsensor is selected from the group consisting of a Hall effect sensor, amagnetoresistive sensor, and an optical sensor.
 11. The surgicalinstrument of claim 1, further comprising a shaft assembly attachable tosaid handle, wherein said shaft assembly comprises a movable jaw, andwherein said movable input comprises a closure trigger configured tomove said movable jaw.
 12. The surgical instrument of claim 1, whereinsaid microcontroller is configured to adjust said reference value. 13.The surgical instrument of claim 1, wherein said surgical instrumentfurther comprises a memory device, and wherein said reference value isstored in said memory device.
 14. The surgical instrument of claim 1,wherein said microcontroller is operated by an algorithm, and whereinsaid reference value is stored in said algorithm.
 15. The surgicalinstrument of claim 1, further comprising a staple cartridge.
 16. Asurgical instrument assembly, comprising: a movable portion; an analogsensor configured to detect the position of said movable portion,wherein said analog sensor is configured to produce an analog signalcomprising analog data; a processor comprising an input channel, whereinsaid analog sensor is in signal communication with said input channel,wherein said processor is configured to compare said analog data to areference value, and wherein said processor is configured to generate adigital signal in response to said comparison.
 17. The surgicalinstrument assembly of claim 16, wherein said microcontroller isconfigured to sample said analog data, wherein said processor comprisesan output channel, wherein said processor is configured to communicatesaid digital signal to said output channel, wherein said reference valuecomprises a first reference value, wherein said processor is configuredto compare said analog data to a second reference value, wherein saidprocessor is configured to change said digital signal if a sample isbelow said first reference value or above said second reference value,and wherein said processor is configured to not change said digitalsignal if a sample is between said first reference value and said secondreference value.
 18. A surgical instrument, comprising: a handlecomprising a trigger, wherein the actuation of said trigger isconfigured to produce a surgical instrument function, and wherein saidtrigger comprises a magnetic element; an analog sensor configured totrack the position of said magnetic element, wherein said analog sensoris configured to produce an analog signal comprising analog data; acontroller, wherein said analog sensor is in signal communication withsaid controller, wherein said controller is configured to compare saidanalog data to a reference value, and wherein said controller isconfigured to produce a digital signal in response to said comparison.19. The surgical instrument of claim 18, wherein said controller isconfigured to sample said analog data, wherein said controller comprisesan output channel, wherein said controller is configured to communicatesaid digital signal to said output channel, wherein said reference valuecomprises a first reference value, wherein said controller is configuredto compare said analog data to a second reference value, wherein saidcontroller is configured to change said digital signal if a sample isbelow said first reference value or above said second reference value,and wherein said controller is configured to not change said digitalsignal if a sample is between said first reference value and said secondreference value.